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Abstract:

Described are methods of making a composite cover material for use in a
thermoplastic core paint roller, the composite cover material formed by
coextruding a smoothly flowing layer comprising a coextrudite comprising
polypropylene-based elastomer and a coextrudite comprising polypropylene
between a pile material and a roller. Each of coextrudites may comprise
calcium carbonate having between 5% and 50% calcium carbonate by weight.

Claims:

1. A method for making composite cover material for use in forming a
laminated paint, the laminated paint roller made by extruding a
polypropylene-based compound to form a smoothly flowing layer of
adhesive, the polypropylene-based compound comprising at least 5% but not
more than 66% calcium carbonate by weight and a polypropylene resin;
applying the adhesive between a composite cover material and one or more
other materials, which, with the adhesive, make up the paint roller core;
and permitting the adhesive to harden and set, thereby creating the paint
roller, the method for making a composite cover material comprising:
advancing a width of material having a pile side and a fabric side, pile
side down, along a tenter; advancing the material from the tenter to a
rotating roller, whereby the material travels along the rotating roller,
pile side towards the rotating roller, for at least a fraction of a
rotation of the first rotating roller; advancing the material from the
rotating roller to a counter-rotating roller, the counter-rotating roller
rotating in the opposite direction as the rotating roller, whereby the
material travels along the counter-rotating roller, fabric side towards
the counter-rotating roller, for at least a fraction of a rotation of the
counter-rotating roller; coextruding a smoothly flowing dual layer of
adhesives between the fabric side of the material and the
counter-rotating roller upstream of the point where the material travels
along the at least a fraction of a rotation of the counter-rotating
roller, thereby sandwiching the coextruded layer between the fabric side
of the material and the counter-rotating roller; and permitting the
coextruded layer to harden and set, thereby causing one side of the layer
of adhesives to bond to the fabric side of the material, thus forming
composite cover material.

2. The method of claim 1, wherein the smoothly flowing dual layer of
adhesives comprises a first coextrudite comprising polypropylene and a
second coextrudite comprising a elastomeric polypropylene, and wherein
coextrusion is performed such that the second coextrudite is extruded on
the material-side, and the first coextrudite is extruded on the
counter-rotating roller side.

3. The method of claim 2, wherein the smoothly flowing dual layer of
adhesives comprises a first coextrudite comprising polypropylene and
between 5 and 66 wt. % calcium carbonate, and a second coextrudite
comprising a elastomeric polypropylene, and wherein coextrusion is
performed such that the second coextrudite is extruded on the
material-side, and the first coextrudite is extruded on the
counter-rotating roller side.

4. The method of claim 2, wherein the smoothly flowing dual layer of
adhesives comprises a first coextrudite comprising polypropylene, and a
second coextrudite comprising a elastomeric polypropylene and between 5
and 66 wt. % calcium carbonate, and wherein coextrusion is performed such
that the second coextrudite is extruded on the material-side, and the
first coextrudite is extruded on the counter-rotating roller side.

5. The method of claim 2, wherein the smoothly flowing dual layer of
adhesives comprises a first coextrudite comprising polypropylene and
between 5 and 66 wt. % calcium carbonate, and a second coextrudite
comprising a elastomeric polypropylene and between 5 and 66 wt. % calcium
carbonate, and wherein coextrusion is performed such that the second
coextrudite is extruded on the material-side, and the first coextrudite
is extruded on the counter-rotating roller side.

Description:

[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 12/687,028, filed Jan. 13, 2010, which is a
continuation-in-part of U.S. patent application Ser. No. 12/435,946,
filed May 5, 2009. The present application is also a continuation-in-part
of U.S. patent application Ser. No. 12/463,876, filed May 11, 2009, which
is a continuation-in-part of U.S. patent application Ser. No. 12/350,798,
filed Jan. 8, 2009. The entire disclosures of each of the priority
applications are incorporated herein by reference.

[0002] This application includes material which is subject to copyright
protection. The copyright owner has no objection to the facsimile
reproduction by anyone of the patent disclosure, as it appears in the
Patent and Trademark Office files or records, but otherwise reserves all
copyright rights whatsoever.

FIELD OF THE INVENTION

[0003] This invention pertains to methods and apparatuses for making paint
rollers of the type used for applying paint to walls and the like. More
specifically, the invention pertains to methods and apparatus for making
a composite cover material for use in a paint roller manufacturing
process, and to making paint rollers that are formed from a composite
cover material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] In the accompanying drawings forming a part of this specification,
and in which like reference characters are employed to designate like
parts throughout the same:

[0005]FIG. 1 is a side view diagrammatic representation of an apparatus
for making composite cover material in accordance with an embodiment of
the present invention.

[0006]FIG. 2 is a side view diagrammatic representation of another
apparatus for making composite cover material in accordance with an
embodiment of the present invention.

[0007]FIG. 3 is a diagrammatic top view of the apparatus for making
composite cover material of FIG. 2.

[0008]FIG. 4 is a side view diagrammatic representation of yet another
apparatus for making composite cover material in accordance with an
embodiment of the present invention.

[0009] FIG. 5 is a diagrammatic top view of the apparatus for making
composite cover material of FIG. 4.

[0010]FIG. 6 is a side view diagrammatic representation of still another
apparatus for making composite cover material in accordance with an
embodiment of the present invention.

[0011]FIG. 7 is a side view diagrammatic representation of a further
apparatus for making composite cover material in accordance with an
embodiment of the present invention.

[0012] FIG. 8 is a side view diagrammatic representation of a still
further apparatus for making composite cover material in accordance with
an embodiment of the present invention.

[0013]FIG. 9 is a side view diagrammatic representation of another
further apparatus for making composite cover material in accordance with
an embodiment of the present invention.

[0014]FIG. 10 is a side view diagrammatic representation of yet another
further apparatus for making composite cover material in accordance with
an embodiment of the present invention.

[0015]FIG. 11 is a side view diagrammatic representation of still another
further apparatus for making composite cover material in accordance with
an embodiment of the present invention.

[0016]FIG. 12 is a diagrammatic representation of an apparatus for making
laminated paint rollers using a composite cover material in accordance
with an embodiment of the present invention.

[0017]FIG. 13 is a diagrammatic representation of another apparatus for
making laminated paint rollers using a composite cover material in
accordance with an embodiment of the present invention.

[0018]FIG. 14 is a diagrammatic representation of an apparatus suitable
for making multi-strip laminated paint rollers using a composite cover
material in accordance with an embodiment of the present invention.

[0019]FIG. 15 is a diagrammatic representation of another paint roller
manufacturing apparatus that can be used in accordance with an embodiment
of the present invention.

[0020]FIG. 16 is a diagrammatic representation of yet another paint
roller manufacturing apparatus that can be used in accordance with an
embodiment of the present invention.

[0021] FIG. 17 is a side-view diagrammatic representation of a further
apparatus for making composite cover material in accordance with an
embodiment of the present invention.

[0022] FIG. 18 is a cutaway side view diagrammatic representation of a
portion of an applicator in accordance with an embodiment of the present
invention.

[0023] FIG. 19 is a diagrammatic side view representation of an apparatus
for sheet-forming according to an embodiment of the present invention.

[0024]FIG. 1 shows an apparatus 801 for forming composite cover material
817. In an embodiment, the apparatus comprises an adhesive applicator 809
that receives a supply of adhesive from an adhesive supply 811 via a
feeder 810, and a strip cutter 816.

[0025] The composite cover material 817 is formed using a supply of pile
material 802 such as would be suitable for use manufacturing a paint
roller cover. The composite cover material is formed using a continuous
supply of pile material such as would be suitable for use manufacturing a
paint roller cover. Suitable pile material 802 may be used such as the
material that can be manufactured using a sliver knitting machine such as
the SK-18 available from Mayer Industries Inc. Such knitted pile material
may be made "in the round," and slit for use as a continuous pile
material. Once slit, the knitted pile material can be laid flat for
further processing. As an alternative to the knitted pile material, a
woven pile material may be used, such a woven pile material, while
generally more expensive than the knitted material, is advantageous as
its fibers are better locked in during the weaving process rather than by
later application of an adhesive. The knitted or woven pile material 2 is
usually sheared (not shown) on the pile side to attain a desired pile
height. As an alternative to woven or knitted materials, a microfiber
material may be used. The material 2 can have any usable width, such as
widths of approximately 32'' or 60'', and can be manufactured or sheared
to a desired pile height. The material 802 can have any usable width, for
example, a width of approximately 32'' or 60''. In an embodiment, the
material has a pile side (shown facing downwards) and a fabric side
(shown facing upwards).

[0026] In an embodiment, the material 802 is laid flat with its pile side
down and moved towards an adhesive layer 802 being dispensed from the
adhesive applicator 809. A tenter (not shown), also known as a tenter
frame, or a similar apparatus may be used to advance the material 802. In
an embodiment, the material 802 is moved in a generally horizontal
direction with the pile side down.

[0027] An adhesive layer 820 is dispensed from the adhesive applicator 809
onto the fabric backing of the material 802. The adhesive supply 811
supplies the adhesive to the applicator 809 via a feeder 810. In an
embodiment, the adhesive is made predominantly or entirely from
polypropylene resin, the adhesive applicator 809 may be a die head and
the supply 811 and feeder 810 are parts of an extruder suitable for use
to extrude polypropylene resin into the adhesive layer 820. After the
adhesive layer 820 has been applied to the fabric backing of the material
802 they are allowed to set and/or bond together. The setting of the
adhesive layer and/or the bonding between the adhesive layer 820 and the
fabric backing of material 802 may be affected by control of the
environment (e.g., the application of heating or cooling, or otherwise)
after the adhesive 820 is dispensed from the applicator 809 but before it
has set fully. It is within the scope of the invention to permit the
setting of the adhesive layer 820 and its bonding to the material 802
through the use of environmental intervention and/or mechanical
intervention.

[0028] In an embodiment, a polypropylene adhesive layer 820 is applied to
the fabric backing of the material 802 in a molten, or at least partially
liquefied state. For the purpose of this document, the term polypropylene
is not intended to require that the adhesive, strip or other material be
made solely of polypropylene, but that it is made predominantly from
polypropylene, and may contain some or a substantial portion of additives
as may be desirable. In an embodiment, after its application to the
fabric backing of the material 802, the molten polypropylene adhesive
layer 802 fills interstitial spaces or gaps within the fabric backing of
the material 802 before setting, thus integrating the adhesive layer 820
with the material 802, and forming a composite sheet material 815. The
thusly formed composite sheet material 815 is stiffer than the material
802 absent the integrated materials from the adhesive layer. In an
embodiment, the fibers of the of the composite sheet material 815 are
locked in place by the integrated materials from the adhesive layer.

[0029] After its application to the fabric backing of the material 802,
the molten polypropylene adhesive layer 802 can set with an even or
smooth exposed surface as it forms the composite sheet material 815 with
a generally uniform non-porous backing.

[0030] The composite sheet material 815 is advanced across cutter 816 to
form composite cover material 817. The cutter 816 may be used to cut the
composite sheet material 815 into strips of composite cover material 817
in a desired width. The strips of composite sheet material 815 do not
need to be cut to equal widths. It is within the scope of this invention
to cut differing width composite cover material 817 from a single
composite sheet material 815, for example, by varying the spacing of the
cutting edges of the cutter 816.

[0031] In an embodiment, the strips of composite cover material 817 each
have a width of approximately 27/8 inches, corresponding to a width of
cover material that may typically be used to manufacture paint rollers.
The composite cover material 817 may be spooled and cut such that it can
be transported for use at another site or on another machine performing a
continuous manufacturing process for laminated paint rollers. In another
embodiment, the composite cover material may be feed directly to an
apparatus that uses the material in forming laminated paint rollers.
Where the composite cover material is spooled, it may be desirable to
spool the composite cover material 817 while it is still warm and
pliable, alternatively, it may be desirable to ensure that the composite
cover material 817 is fully cooled (i.e., not warm and pliable) when it
is spooled.

[0032] If the pile on material 802 had not been sheared to the desired
height prior to the application of the adhesive layer 820, the composite
sheet material 815, or the composite cover material 817 may be cut by a
pile cutter (not shown). The additional rigidity of the composite sheet
material 815 or composite cover material 817 (as compared to the material
802) may make the process of shearing to a desired pile height easier.

[0033]FIG. 2 shows an apparatus 801A for forming composite cover material
817. In an embodiment, the apparatus comprises an adhesive applicator
809, an environmental control 807 and a strip cutter 816. The adhesive
applicator 809 receives a supply of adhesive from an adhesive supply 811
via a feeder 810.

[0034] Composite cover material 817 is formed using a supply of pile
material 802 such as would be suitable for use manufacturing a paint
roller cover. Pile material 802 is a type suitable for use as a paint
roller, and in an embodiment may be knitted or woven material. The
material 802 can have any usable width, for example, a width of
approximately 32 inches, or of approximately 60 inches. In an embodiment,
the material has a pile side (shown facing upwards) and a fabric side
(shown facing downwards).

[0035] In an embodiment, the material 802 is laid flat with its pile side
down and moved towards an adhesive layer 802 being dispensed from the
adhesive applicator 809. A tenter (not shown) or a similar apparatus may
be used to advance the material 802. In an embodiment, the material 802
is moved in a generally horizontal direction with the pile side down.

[0036] An adhesive layer 820 is dispensed from the adhesive applicator 809
onto the fabric backing of the material 802. The adhesive supply 811
supplies the adhesive to the applicator 809 via a feeder 810. In an
embodiment, the adhesive is made predominantly or entirely from
polypropylene resin, the adhesive applicator 809 may be a die head and
the supply 811 and feeder 810 are parts of an extruder suitable for use
to extrude polypropylene resin into the adhesive layer 820. Once the
adhesive layer 820 has been applied to the fabric backing of the material
802 they are allowed to set and/or bond together.

[0037] The setting of the adhesive layer and/or the bonding between the
adhesive layer 820 and the fabric backing of material 802 may be affected
by control of the environment (e.g., the application of heating or
cooling, or otherwise) after the adhesive 820 is dispensed from the
applicator 809 but before it has set fully. It is within the scope of the
invention to permit the setting of the adhesive layer 820 and its bonding
to the material 802 through the use of environmental intervention.

[0038] In an embodiment, after the application of the adhesive layer 820
the material 812 can be fed through an environmental control 807 as it
forms the composite sheet material 815. The environmental control 807 may
be used to affect the bond, or the quality or completeness of the bond,
between the adhesive layer 820 to the underlying material 802, and aid in
integrating the adhesive layer 820 with the material 802.

[0039] In an embodiment using an environmental control 807, the control
807 may employ the application of heat, which may even or smooth the
exposed surface of the adhesive layer 820.

[0040] In an embodiment using an environmental control 807, the control
807 may employ the application of heat, which may permit the adhesive in
the adhesive layer 820 to better fill interstitial spaces or gaps within
the material 802.

[0041] In an embodiment using an environmental control 807, the control
807 may employ the application of heat, which may allow more contact
between the adhesive in the adhesive layer and the fibers making up the
pile in the material 802, thereby locking fibers in place in the pile as
it sets.

[0042] In an embodiment using an environmental control 807, the control
807 may employ the application of heat, which can provide the ability to
control the speed at which the adhesive sets and creates the composite
sheet material 815.

[0043] In another embodiment using an environmental control 807, the
control 807 may employ cooling, such cooling can hasten the hardening or
setting of the adhesive layer 820.

[0044] It is within the scope of the invention to employ an environmental
control 807 that utilizes both the application of heat and the
application of cold, seriatim, in any order, and without limitation on
the number of applications or the temperature of a specific application.

[0045] Using heat, cooling, multiple applications of heat or cooling, or
combinations of both heat and cooling may achieve, among other things,
one or more of the following: (i) evening or smoothing the exposed
surface of the adhesive layer 820 to provide a generally uniform
non-porous backing; (ii) permitting the adhesive in the adhesive layer
820 to better fill interstitial spaces or gaps within the material 802;
and/or (iii) allowing more contact between the adhesive in the adhesive
layer and the fibers making up the pile in the material 802; (iv) locking
fibers in the pile in place as the adhesive sets; and/or (v) hasten or
lengthening the hardening or setting of the adhesive layer 820.

[0046] Whether or not an environmental control 807 is employed, the
composite sheet material 815 is advanced across cutter 816 to form
composite cover material 817. As discussed above, the cutter 816 may be
used to cut the composite sheet material 815 into strips of composite
cover material 817 in a desired width. The strips of composite sheet
material 815 do not need to be cut to equal widths. It is within the
scope of this invention to cut differing width composite cover material
817 from a single composite sheet material 815, for example, by varying
the spacing of the cutting edges of the cutter 816.

[0047] In an embodiment, the strips of composite cover material 817 each
have a width of approximately 27/8 inches, corresponding to a width of
cover material that may typically be used to manufacture paint rollers.
As discussed above, composite cover material 817 may be spooled and cut
for transport, or feed directly to an apparatus that uses the material in
forming laminated paint rollers. The composite cover material 817 may be
spooled while it is still warm and pliable, or after it is fully cooled.

[0048] If the pile on material 802 has not been sheared to the desired
height prior to the application of the adhesive layer 820, a pile cutter
(not shown) can be use to shear the composite sheet material 815 or the
composite cover material 817.

[0049]FIG. 3 shows a top view is shown of an apparatus 801A for
manufacturing the composite cover material 817 in accordance with an
embodiment of the invention. The adhesive applicator 809 applies an
adhesive layer 820 to the material 802 as the material is advanced. In an
embodiment, the material 802 may be fed into the apparatus 801A directly
as it is manufactured, or from pre-manufactured lengths.

[0050] In the embodiment shown in FIG. 3, the fabric-backed pile material
802 approximately 32'' wide is advanced. A polypropylene adhesive layer
820, which starts wider at the applicator 809 is narrowed as it is pulled
along by the advancing material 802. Where the adhesive layer 820 makes
contact with the material 802, it may be between 315/8'' and 32''. The
adhesive layer 802 and advancing material 802 passed through
environmental control 807. Smooth composite sheet material 815 emerges
from the environmental control 807 and is separated into eleven strips of
composite cover material 817, each being 27/8'' wide. Twelve separate
blades can be used in the cutter 816 to form the eleven strips of 27/8''
each, and two small waste strips 31.

[0051] Varying the width of the material 802 is within the scope of the
invention, thus, in another embodiment, the material 802 can be
approximately 60'' wide, and narrowed width of the adhesive layer 820
where it contacts the material 802 is between 57.5'' and 60'' wide. Using
this configuration, and twenty-one blades for cutter 16, twenty strips of
27/8'' composite cover material can be made. As above, two small waste
strips 31 will result.

[0052] While only two different examples are presented, any desired width
of material 802 may be used. Where the adhesive layer 820 comprises
polypropylene, and where the applicator 809 is an extruder, one limiting
factor on the width of the material 802 used is the capabilities of the
extruder. It is, however, within the scope of the invention to use
multiple extruders to apply multiple, non-overlapping adhesive layers 802
on the material 802.

[0053]FIG. 4 shows an apparatus 801B for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive
applicator 809 fed from a feeder (not shown) which gets a supply of
adhesive from an adhesive supply (not shown). An advancing material 802
is deposited by an applicator 809 onto a roller 880, and runs between the
roller 880 and a frame 890 having a flat portion. The roller 880 may be
urged toward the frame 890 by a spring, by gravity or by other means that
will be apparent to persons skilled in the art.

[0054] Composite cover material 817 is formed using a supply of pile
material 802 such as would be suitable for use manufacturing a paint
roller cover. The material 802 is a type suitable for use as a paint
roller, and in an embodiment may be knitted or woven material. The
material 802 can have any usable width, for example, a width of
approximately 32 inches, or of approximately 60 inches. In an embodiment,
the material has a pile side (shown facing upwards) and a fabric side
(shown facing downwards).

[0055] In an embodiment, the material 802 is supported by a frame 809 such
as a tenter frame with its pile side down, and moved towards the roller;
an adhesive layer 820 is dispensed from the adhesive applicator 809. The
frame or a similar apparatus may be used to advance the material 802. The
adhesive layer may be any operable thickness. In an embodiment, the
adhesive layer 820 is between 0.010'' and 0.020'' in thickness.

[0056] Once the adhesive layer 820 dispensed from the applicator 809
contacts the roller 880, it travels along on the outside of the roller
until it is sandwiched between the roller 880 and the material 802. The
positioning and angular orientation of the applicator 809 may be varied.
In an embodiment, the applicator is angled between 30 degrees and 60
degrees from vertical and positioned within inches of the middle of the
roller 880. In another embodiment the applicator 809 is within 30 degrees
(+/-) of vertical, and is positioned to dispense adhesive such that the
adhesive layer 820 first makes contact on the upper half of the roller
880. In yet another embodiment, the applicator 809 is within 30 degrees
(+/-) of horizontal and is positioned to dispense adhesive such that the
adhesive layer 820 first makes contact on the lower half of the roller
880. Variations in the angular orientation of the applicator 809, and its
distance from and orientation around the roller are within the scope of
the invention, and will be apparent to one skilled in the art.

[0057] In an embodiment, the adhesive is made predominantly or entirely
from polypropylene resin and the adhesive applicator 809 may be a die
head that is part of an extruder suitable for use to extrude
polypropylene resin into the adhesive layer 820. In such an embodiment,
the adhesive has a viscosity as it exits the extruder in the form of a
sheet of molten polypropylene. The applicator 809 may be placed
relatively close to the location where the adhesive layer 802 contacts
the roller 880 (as shown); alternatively, in an embodiment, the
applicator 809 may be placed farther away, or at another location where
the adhesive layer 820 contacts the roller 880 sooner before it contacts
the material 802, or after it contacts the material 802. Such variation
is within the scope of this invention, and will be apparent to a person
of skill in the art.

[0058] As the material 802 and the adhesive layer 820 pass between the
roller 880 and the surface of the frame 890 they are urged together. The
top or roller-side of the adhesive layer 820 may be smoothed or uniformly
imprinted (e.g., embossed) as it passed underneath the roller 880 forming
a uniform or smooth adhesive layer surface 851. The compressive force of
the roller 880 may be sufficient to force adhesive into the interstitial
spaces or gaps in the fabric backing of the material 802. The resulting
composite sheet material 815 may be cut by cutter 816 to form the
composite cover material 817 with a non-porous backing.

[0059] The roller 880 may be heated. Heating of the roller 880 may aid in
the penetration of the adhesive layer 820 into the interstitial spaces or
gaps within the material 802 as the adhesive layer 820 passes beneath the
roller 880.

[0060] The roller 880 may be cooled. Cooling of the roller 880 may hasten
the setting of the adhesive layer 820 or of the uniform or smooth
adhesive layer surface 851, or both. Hastening the setting of the uniform
or smooth adhesive layer surface 851 may yield a crisper imprint or a
smoother surface thereon. Even if the roller 880 is cooled, the
compressive force of the roller 880 may be sufficient to force adhesive
into the interstitial spaces or gaps in the fabric backing of the
material 802. Thus, a cooled roller may provide one or more of the
following benefits: providing a smoother or crisper surface 851;
hastening the setting of the adhesive, and thus the forming of the
composite sheet material 815; improving the contact between the material
802 and the adhesive used to form the adhesive layer 820; and holding in
place of the fibers comprising the pile of the material 802.

[0061] The roller 880 may also be operated at ambient temperature, and
neither heated nor cooled. In an embodiment, the roller 880 is of a
diameter that will allow it to adequately smooth or uniformly imprint the
adhesive layer 820 to form the smoothed or uniform adhesive layer 851. In
an embodiment, the roller 880 has a diameter between about 14'' and 20''.

[0062]FIG. 5A shows a top view of the apparatus 801B. The material 802
advances across frame 890 (not shown). The applicator 809 dispenses an
adhesive layer (not show) on the upper surface of the material 802. The
material 802 with the adhesive layer thereupon are passed beneath a
roller 880 which imparts a compressive force thereupon. The top or
roller-side of the adhesive layer 820 may be smoothed or uniformly
imprinted as it passed underneath the roller 880 forming a uniform or
smooth adhesive layer surface 851 while the compressive force of the
roller 880 may be sufficient to force adhesive into the interstitial
spaces or gaps in the fabric backing of the material 802. The resulting
composite sheet material 815 may be cut by cutter 816 to form the
composite cover material 817 with a non-porous backing.

[0063]FIG. 6 shows an apparatus 801C that is a variation on the apparatus
801B shown in FIGS. 4 and 5A. More specifically, apparatus 801C
additionally includes roller 881, that acts, together with roller 880, to
impart a compressive force between the material 802 and the adhesive
layer 820. The roller is shown in a modified frame 891 that allows for
the rollers 880, 881 to act together as the material 802 and adhesive
layer 820 pass beneath the upper roller 880.

[0064] As discussed above with respect to the roller 880, the roller 881
can be heated or cooled. It is thus possible to simultaneously heat or
cool the rollers 880, 881. It is also possible to heat or cool one of the
rollers, or to heat one of the rollers, while cooling the other.

[0065] In an embodiment, the upper roller 880 is cooled while the lower
roller 881 is heated. Cooling the upper roller 880 may provide one or
more of the following benefits: providing a smoother or crisper surface
851; hastening the setting of the adhesive, and thus the forming of the
composite sheet material 815; improving the contact between the material
802 and the adhesive used to form the adhesive layer 820; and holding in
place of the fibers comprising the pile of the material 802. While
heating the lower roller 881 may aid in the penetration of the adhesive
layer 820 into the interstitial spaces or gaps within the material 802 as
the adhesive layer 820 passes above the roller 881.

[0066] Either or both of the rollers may also be operated at ambient
temperature, and neither heated nor cooled.

[0067] Moreover, it is not necessary to modify the frame 890 shown in FIG.
4 to be like the frame 891 shown in FIG. 6 to operate rollers 880, 881 in
order to keep within the scope of the present invention. As will be
apparent to one of skill in the art, the rollers 880, 881 can be
configured to be prior to, or after, an unmodified frame 891. The
applicator 809 can be moved accordingly.

[0068] The rollers 880, 881 may be the same size, or of differing sizes.
In an embodiment, the upper roller 880 is of a diameter that will allow
it to adequately smooth or uniformly imprint the adhesive layer 820 to
form the smoothed or uniform adhesive layer 851. In an embodiment, the
upper roller 880 has a diameter between about 14'' and 20''. In an
embodiment, the lower roller 881 is of a diameter that will permit it to
operate with the upper roller 880. In an embodiment, the lower roller 880
has a diameter between about 5'' and 20''.

[0069] In an embodiment, instead of using a tenter to move the material,
the rollers 880, 881 can drive the material therebetween.

[0070] Turning now to FIG. 7, an apparatus 801D for forming the composite
cover material 817 is shown. In an embodiment, the apparatus comprises an
adhesive applicator 809 fed from a feeder (not shown) which gets a supply
of adhesive from an adhesive supply (not shown). An advancing material
802 runs between a roller 880 and a surface 890 such as a flat portion of
a tenter frame. The roller 880 may be urged toward the surface 890 by a
spring, by gravity or by other means that will be apparent to persons
skilled in the art.

[0071] An adhesive layer 820 leaves the applicator 809 and is sandwiched
between the roller 880 and the material 802 prior to, or as the material
passes beneath the roller 880. In an embodiment, the adhesive forming the
adhesive layer 820 is predominantly polypropylene. The positioning of the
applicator 809 may be varied. Where the adhesive forming the adhesive
layer 820 is polypropylene, the applicator 809 may be the die head of an
extruder. In such an embodiment, the adhesive has a viscosity as it exits
the extruder that forms a sheet of molten polypropylene. In an
embodiment, the applicator 809 may be placed at a distance to the
location where the adhesive layer contacts the material 802 prior to
contacting the roller 880 (as shown) or at substantially the same time it
contacts the roller 880; or at another location, including where the
adhesive layer 820 contacts the roller 880 before it contacts the
material 802. Such variation is within the scope of this invention, and
will be apparent to a person of skill in the art.

[0072] As the material 802 and the adhesive layer 820 pass between the
roller 880 and the surface 890 they are urged together. The top or
roller-side of the adhesive layer 820 is smoothed or uniformly imprinted
as it passed underneath the roller 880 forming a uniform or smooth
adhesive layer 851, while the contact between the adhesive and the
material 802 under pressure from the roller 880 permits the adhesive
layer 820 to fill interstitial spaces or gaps within the material 802.
The material 802 and the uniform or smooth adhesive layer 851 may then be
passed beneath a second roller 884 to form the resulting composite sheet
material 815.

[0073] After the material 802 with the applied adhesive layer 820 pass
between the roller 880 and the surface 890 forming the uniform or smooth
adhesive layer 851, the combination is then passed beneath a second
roller 884. As with the first roller 880, when the combination passes
beneath the second roller 884 it is again urged together. The second
roller 884 may also smooth or imprint the uniform or smooth adhesive
layer 851, and in any event, will impart downward pressure upon it, which
may permit the adhesive layer 820 to further fill interstitial spaces or
gaps within the material 802. The resulting composite sheet material 815
may be cut by cutter 816 to form the composite cover material 817 with a
non-porous backing.

[0074] One or both of the rollers 880, 884 may be heated or cooled, or one
may be heated while the other is cooled.

[0075] Cooling one or both of the rollers 880 may provide one or more of
the following benefits: providing a smoother external surface or crisper
imprint; hastening the setting of the adhesive, and thus hastening the
forming of the composite sheet material 815; improving the contact
between the material 802 and the adhesive used to form the adhesive layer
820; and holding in place of the fibers comprising the pile of the
material 802. Heating the rollers 880, 884 may aid in the penetration of
the adhesive layer 820 into the interstitial spaces or gaps within the
material 802 as the adhesive layer 820 passes beneath the rollers 880,
884 and may permit for better imprinting into, or smoothing of, the
external surface of the adhesive layer 820.

[0076] Either or both rollers 880, 884 may also be operated without
heating or cooling.

[0077] The diameter of each of the rollers 880, 881, and whether each of
them are heated, or cooled, or neither heated nor cooled, depends upon
the specific function desired for the roller. Such variations are within
the scope of the present invention.

[0078] FIG. 8 shows an apparatus 801E for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive
applicator 809 fed from a feeder (not shown) which gets a supply of
adhesive from an adhesive supply (not shown). An advancing material 802
runs between rollers 880, 882, 883 and a surface 890 such as a flat
portion of a tenter frame. The rollers 880, 882, 883 may be urged toward
the surface 890 by a spring, by gravity or by other means that will be
apparent to persons skilled in the art.

[0079] An adhesive layer 820 leaves the applicator 809 and falls upon the
first roller 880. As the first roller 880 rotates, the adhesive layer 820
comes into contact with the material 802. The positioning of the
applicator 809 may be varied. In an embodiment where the adhesive forming
the adhesive layer 820 is polypropylene, the applicator 809 may be the
die head of an extruder. In such an embodiment, the adhesive has a
viscosity as it exits the extruder that forms a sheet of molten
polypropylene. In an embodiment, the applicator 809 may be placed above
the roller 880 such that it contacts the roller before the material 802
(as shown); or at another location where it will still make contact with
the roller 880 before it contacts the material 802. Such variation is
within the scope of this invention, and will be apparent to a person of
skill in the art.

[0080] In an embodiment, the adhesive forming the adhesive layer 820 is
polypropylene. As the material 802 and the adhesive layer 820 pass
between the rollers 880, 882, 883 and the surface 890 they are urged
together. As discussed above, each of the rollers 880, 882, 883 may be
heated or cooled, or may be neither heated nor cooled. Also as discussed
above, the rollers 880, 882, 883 may be of the same size, or of varying
size. In an embodiment, the rollers 880 882, 883 are each in the range of
14'' to 20''. In an embodiment, the first roller 880 is in the range of
14'' to 20'', while the second and third rollers 882, 883 are smaller
than the first roller 880, and are in the range of 10'' to 18''.
Selection of the diameters and thermal characteristics of the rollers
880, 882, 883 may be to achieve desired results.

[0081] The composite sheet material 815 may be cut by cutter 816 to form
the composite cover material 817 with a non-porous backing.

[0082]FIG. 9 shows an apparatus 801E for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive
applicator 809, a feeder and adhesive supply (not shown), rollers 850 and
strip cutter 816. After the adhesive layer 820 leaves the applicator 809,
but before it contacts the material 802, the rollers 850 smooth the
adhesive layer 820 to form a smoothed adhesive layer 851. In an
embodiment where the adhesive is polypropylene, although smoothed
adhesive layer 851 may be cooler than it was leaving the applicator 809,
it is still not hardened or set. Thus, after the smoothed adhesive layer
851 contacts the material 802, it can harden and set forming the
composite sheet material 815. The composite sheet material 815 may be cut
by cutter 816 to form the composite cover material 817 with a non-porous
backing.

[0083]FIG. 10 shows an apparatus 801F for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive
applicator 809, a feeder and an adhesive supply (not shown), rollers 850,
rollers 852 and strip cutter 816. After the adhesive layer 820 leaves the
applicator 809, but before it contacts the material 802, the rollers 850
smooth the adhesive layer 820 to form a smoothed adhesive layer 851. In
an embodiment where the adhesive is polypropylene, although smoothed
adhesive layer 851 may be cooler than it was leaving applicator 809, it
is still not hardened or set. After the smoothed adhesive layer 851
contacts the material 802, the rollers 852 apply a compressive force
compressing the smoothed adhesive layer 851 and the material 802 together
to form the composite sheet material 815. The rollers 852 may also be
used to uniformly imprint the smoothed adhesive layer 851. The composite
sheet material 815 may be cut by cutter 816 to form the composite cover
material 817 with a non-porous backing.

[0084] In an embodiment, the rollers 852 are heated to a temperature
hotter than the temperature of smoothed adhesive layer 851. In an
embodiment, the rollers 852 are cooled to a temperature cooler than the
temperature of the smoothed adhesive layer 851. In an embodiment, the
rollers 852 are neither heated nor cooled. In an embodiment, one of the
rollers 852 is heated while the other is cooled.

[0085]FIG. 11 shows an apparatus 801G for forming the composite cover
material 817. In an embodiment, the apparatus comprises an adhesive
applicator 809, a feeder and an adhesive supply (not shown), three roller
pairs 850, 855, 860 and strip cutter 816. After the adhesive layer 820
leaves the applicator 809, but before it contacts the material 802, the
roller pair 850 may smooth the adhesive layer 820 to form a smoothed
adhesive layer 851. In an embodiment the adhesive is predominantly
polypropylene, and although smoothed adhesive layer 851 may be cooler
than it was when leaving applicator 809, it is still not hardened or set.
After the smoothed adhesive layer 851 contacts the material 802, the
second roller pair 852 applies a compressive force compressing the
smoothed adhesive layer 851 and the material 802 together while at the
same time imparting heat to the combination. The third roller pair 860
thereafter applies a compressive force compressing the smoothed adhesive
layer 851 and the material 802 together, while it may, at the same time,
cool them. It is believed that the heating by rollers 852 may aid in
filling interstitial spaces or gaps within the material 802 with
contacting side of the smoothed adhesive layer 851, and that the cooling
by the second cooling rollers 860 may hasten the setting of the smoothed
adhesive layer. The resulting composite sheet material 815 may be cut by
cutter 816 to form the composite cover material 817 with a non-porous
backing.

[0086]FIG. 12 shows a diagrammatic representation of an apparatus 900
suitable for making laminated paint rollers in accordance with an
embodiment of the invention. For ease of discussion in this application,
the term "downstream" refers to the direction further along in the roller
manufacturing process, or nearer the fly-away cutter 27, while the term
"upstream" refers to the direction earlier in the roller manufacturing
process, or further from the fly-away cutter 27.

[0087] Housing 22 supports mandrel 21. A cooler (not shown) can be used to
cool the mandrel 21. In an embodiment, inner strip 23 is fed about the
mandrel 21, so it winds helically. The term helically as used herein
means oriented about a mandrel 21 so as to permit the upstream edge of a
given wind of a strip or cover material to be in closely-spaced or
abutting relation with the downstream edge of the preceding wind of the
strip. A lubricant such as 5% mineral oil may be applied to the inner
surface of the inner strip 23 prior to winding on the mandrel 21.

[0088] The head 24 provides a layer of adhesive material 25 from a source
of such material (not shown), the adhesive material 25 may be
polypropylene or a compound predominantly made of polypropylene. The
source of adhesive material 25 may be an extruder, or may be another
source of adhesive material, such as a melter. The head 24 may be any
type of head appropriate for providing adhesive material 25 from the
source, such as a nozzle or a die. Where the source of polypropylene
adhesive material 25 is an extruder, the head 24 is preferably a die.

[0089] In an embodiment a single head 24 supplies an adhesive layer 25 to
the outer surface of inner strip 23 as it rotates around the mandrel 21.
Although the width of the adhesive layer may be varied, in an embodiment,
the width of the adhesive layer 25 should substantially cover the outer
surface of the inner strip 23. The width of the adhesive layer 25,
however, may not completely cover the outer surface of the inner strip
23, or may be sufficient to excess adhesive over the amount required to
completely cover the outer surface of inner strip 23. A strip of
composite cover material 817 is advanced about the mandrel 21 outside of
the inner strip 23 and adhesive layer 25. In an embodiment, composite
cover material 817 comprises an outer surface of pile and a smooth or
uniformly imprinted inner surface or backing made of polypropylene or a
compound predominantly made of polypropylene.

[0090] The edges of the composite cover material 817 may be offset from
the edges of the inner strip 23 as the two are advanced along the mandrel
21. It is believed that the a stronger product is yielded from having an
offset between the edge of the composite cover material 817 and the edge
of the inner strip 23. An offset of between about one-quarter and
three-quarters of the width of the inner strip 23 is found to achieve
acceptable results. Good results may be achieved by having an offset of
about one-half of the width of the inner strip 23.

[0091] Prior to the hardening and setting of the adhesive material 25, an
inwardly compressive force applies pressure to the outer pile surface of
the composite cover material 817, imparting inward forces on the
component parts, thus laminating the composite cover material 817 and the
inner strip 23 as the adhesive layer 25 sets. The continuous roller 929
is thereby formed about the mandrel 21.

[0092] In an embodiment, the inwardly compressive force is a helical belt
system formed from rollers 28a, 28b, and a belt 28. In addition to
compressing the component parts and forming the roller, the belt 28
advances the thus-formed endless roller 929 along the mandrel 21 and
continuously rotates the endless roller, thereby also advancing the inner
strip 23 and the composite cover material 817 around and downstream on
the mandrel 21.

[0093] The endless roller 929 may be cut by the fly-away saw 27, into
lengths after it has sufficiently set. The fly-away saw 27 may be used to
cut endless roller 929 into paint-roller sized lengths ready for
finishing, or more typically into sticks 926 of a fixed length, such as
65'', that may be further cut and finished into paint-rollers.

[0094] It is within the scope of the invention to apply the adhesive layer
25 to the outer surface of the inner strip 23, the inner smooth or
imprinted surface of the composite cover material 817, or simultaneously
to the smooth or imprinted inner surface of the composite cover material
817 and the outer surface of the inner strip 23, in any event, such that
the adhesive layer 25 is sandwiched between the inner strip 23 and the
composite cover material 817.

[0095] In an embodiment, the head 24 is a die head, and the adhesive layer
25 is predominantly or entirely from polypropylene. An extruder (not
shown) forces the thermoplastic through the head 24, thereby dispensing a
molten adhesive layer 25.

[0096] The present invention creates a laminated paint roller from a
single strip of polypropylene 23 (or made predominantly of
polypropylene), a single strip of composite cover material 817, and a
single die head 24 that produces a layer of adhesive material 25 that is
approximately as wide the width of the inner strip 23. The simple
manufacturing line produces a laminated paint roller, with a low hoop
force, which does not suffer from being out of round at its ends after
being finished and cut. The lower hoop force can be demonstrated by
slicing the a finished laminated paint roller lengthwise, and observing
that it does not tend to open flat, but rather tends to keep its round
shape as would an extruded plastic tube.

[0097] In an embodiment, the inner strip 23 has a width of 23/4 inches,
and a thickness of between about 0.010'' and 0.030''; the composite cover
material 817 has approximately the same thickness, not counting the pile
height, and a width of 27/8 inches; and the adhesive layer may be between
0.010 inches and 0.030 inches. Thicknesses selected from the higher
values in these ranges will provide paint rollers that have a more rigid
feel, while thicknesses selected from the lower values in the ranges will
provide a paint roller that has a softer feel. It is within the scope of
the invention to independently select each of the thicknesses from these
ranges. The width and thickness of the inner strip 23, and the width,
non-pile thickness and pile thickness of the composite cover material 817
may be those that are appropriate for manufacture of the desired roller.
For example, a typical high quality laminated roller having a 1.5-inch
diameter core and a 75-wall can be manufactured with the following
materials:

[0098] As used herein, the term "wall" or "mil" means thickness in
thousandths of an inch. Such widths and thickness and the methods of
determining them will be apparent to one of skill in the art; almost
infinite variation is possible depending upon the characteristics of the
desired roller.

[0099] It is presently believed that the lamination process of the present
invention will produce commercially acceptable rollers having a 1.5-inch
diameter core manufactured with any of the following combinations of
materials:

[0100] Variations of this type with respect to the present invention will
be apparent to one skilled in the art. The amount of adhesive required is
expected to be less than may be required in a process bonding a
polypropylene strip to cover material such as material 802 (FIG. 1, et
seq.). This is expected because the adhesive layer bonds only two smooth
(or uniform) non-porous layers rather than a smooth layer with a porous
material.

[0101] In another embodiment (not shown), the composite cover material 817
can be directly fed from a machine producing it (e.g., the apparatus 801B
in FIG. 4) into a paint roller manufacturing apparatus 900 for making
laminated paint rollers. It is within the scope of the invention to
combine multiple composite cover material 817 strips, such as, for
example, using a fly-away to cutter to cut the composite cover material
817 into fixed-length sections, and using a fastening means to attach the
ends of such fixed-length sections as the composite cover material 817 is
consumed by the manufacturing of paint rollers using a paint roller
manufacturing apparatus 900. In this manner, depending on the relative
speed of the paint roller manufacturing apparatus 900, the machine
producing the composite cover sheet 815 (see FIG. 4), the manufactured
width of composite cover sheet 815 (see FIG. 4) and the desired width of
composite cover material 817 (see FIG. 4), multiple paint roller
manufacturing apparati 900 can be supplied from one apparatus 801B making
composite cover material 817.

[0102]FIG. 13 shows a diagrammatic representation of an apparatus 950
suitable for making laminated paint rollers in accordance with an
embodiment of the invention. In an embodiment, the apparatus comprises a
first adhesive applicator 809 having a feeder and an adhesive supply (not
shown), rollers 880, 881 and a cutter 816. The composite cover material
817 is formed using a supply of pile material 802, having a pile side and
a fabric side, and suitable for use manufacturing a paint roller cover.
The pile material 802 is laid flat for processing. The material 802 may
be sheared (not shown) on the pile side to attain a desired pile height
prior to processing by the machine 950. The material 802 can be in any
convenient width. In an embodiment, material 802 has a width of
approximately 32''.

[0103] In an embodiment, an adhesive layer 820 is applied to the fabric
side of the material 802 by the adhesive applicator 809. The adhesive
supply (not shown) supplies the adhesive to the applicator 809 by a
feeder (not shown). In an embodiment, the adhesive is made predominantly
or entirely from polypropylene resin, the adhesive applicator may be an
extruder comprising a die head 809.

[0104] After the adhesive layer 820 is applied to the fabric side of the
material 802, a compressive force urging the adhesive layer and the
material 802 together is imparted by rollers 880, 881. The upper roller
880 smoothes and/or imprints the exterior surface of the adhesive layer
forming a smoothed or imprinted layer 851. The thus-formed composite
sheet material is then permitted to cool and set. Such cooling and
setting can be hastened by a cooling system (not shown) which can impart
cooling to the combined sheet material 815 by any method, including,
without limitation, a cooled roller or the flow of cool air or other gas
or fluids. In an embodiment, the adhesive layer 820 comprises
predominantly or entirely polypropylene. The fibers in the material 802
are further held in place by the adhesive layer 820 after it has cooled
and set.

[0105] Either before or after the applied adhesive layer 820 is completely
set, the composite sheet material 815 is advanced toward a cutter 816.
The cutter 816 is used to cut the composite sheet material into strips of
composite cover material 817 having a pile side and a smooth and/or
imprinted side predominantly or entirely made of polypropylene. In an
embodiment, the strips of composite cover material are each approximately
27/8 inches wide corresponding to a width of a cover strip that may be
then used to manufacture paint rollers.

[0106] In an embodiment, eleven strips of composite cover material 817
each being 27/8 inches wide are formed from a width of approximately 32''
of the material 802. This width allows for a relatively small amount of
waste on each side of the composite sheet material 815 as it is cut by
the cutter 816 and thereby becomes composite cover material 817.

[0107] Although the composite cover material 815, or the strips of
composite cover material 817 could be spooled and cut (not shown) for
transportation to another site or another machine performing a
manufacturing process for laminated paint rollers in accordance with the
present invention, in an embodiment, the composite cover material 817 is
fed directly to a mandrel 21. Housing 22 supports the mandrel 21. A
cooler (not shown) can be used to cool the mandrel 21. In an embodiment,
an inner strip 23 is made from or predominantly made from polypropylene.
The inner strip 23 is feed about a the mandrel 21 so it winds helically.

[0108] The head 24 provides a layer of adhesive material 25 from a source
of such material (not shown). The layer of adhesive material 25 is
preferably polypropylene or made predominately from polypropylene. The
polypropylene material is preferably supplied by an extruder (not shown)
to head 24 that is a die.

[0109] In an embodiment a single head 24 dispenses a layer of adhesive
material 25 to the outer surface of inner strip 23 as it rotates around
the mandrel 21. Although the width of the layer of adhesive material may
be varied, in an embodiment, the width the layer of adhesive material 25
should substantially cover the outer surface of the inner strip 21. The
width of the layer of adhesive material 25, however, may not completely
cover the outer surface of the inner strip 21, or may in an embodiment be
sufficient to provide excess adhesive over the amount required to
completely cover the outer surface of inner strip 21. The strip of
composite cover material 817 is advanced from the cutter 816 toward, and
then about the mandrel 21 outside of the inner strip 23 and the layer of
adhesive material 25.

[0110] The edges of the composite cover material 817 may be offset from
the edges of the inner strip 23 as the two are advanced along the mandrel
21. It is believed that a stronger product is yielded from having an
offset between the edge of the composite cover material 817 and the edge
of the inner strip 23. An offset of between about one-quarter (as shown)
and three-quarters of the width of the inner strip 23 is found to achieve
acceptable results. Good results are achieved by having an offset of
about one-half of the width of the inner strip 23.

[0111] Prior to the hardening and setting of the layer of adhesive
material 25, an inwardly compressive force applies pressure to the outer
surface of the composite cover material 817, imparting inward forces on
the component parts, thus laminating the composite cover material 817 and
the inner strip 21 as the adhesive layer 25 sets. The continuous roller
929 is thereby formed about the mandrel 21.

[0112] In an embodiment, the inwardly compressive force is a helical belt
system formed from rollers 28a, 28b, and a belt 28. In addition to
compressing the component parts and forming the roller, the belt 28
advances the thus-formed endless roller 929 along the mandrel 21 and
continuously rotates the endless roller, thereby also advancing the inner
strip 23 and the composite cover material 817 around and downstream on
the mandrel 817.

[0113] The endless roller 929 may be cut by the fly-away saw 27, into
lengths after it has sufficiently set. The fly-away saw 27 may be used to
cut endless roller 929 into paint-roller sized lengths ready for
finishing, or more typically into sticks 926 of a fixed length, such as
65'', that may be further cut and finished into paint-rollers.

[0114] It is within the scope of the invention to apply the adhesive layer
25 to the outer surface of the inner strip 23 (shown), the inner surface
of the composite cover material 817 not shown, or simultaneously to the
inner surface of the composite cover material 817 and the outer surface
of the inner strip 23, in any event, such that the adhesive layer 25 is
sandwiched between the inner strip 23 and the composite cover material
817.

[0115]FIG. 14 shows a diagrammatic representation of an apparatus 410
suitable for making laminated paint rollers in accordance with another
embodiment of the invention. Housing 22 supports mandrel 21. A cooler
(not shown) can be used to cool the mandrel 21. In an embodiment, inner
strip 23 is fed about the mandrel 21, so it winds helically. A lubricant
such as 5% mineral oil may be applied to the inner surface of the inner
strip 23 prior to winding on the mandrel 21. Second strip 423 is feed
about the mandrel 21 and inner strip 23, so it winds helically, and in
offset relation to inner strip 23.

[0116] The head 424 provides a layer of adhesive material 425 from a
source of such material (not shown), the adhesive material 425 preferably
is or comprises predominately polypropylene. The source of adhesive
material 425 is preferably an extruder, but may be any source of adhesive
material including a melter. The head 424 may be any type of head
appropriate for providing adhesive material 425 from the source, such as
a nozzle or a die. Where the source of the adhesive material 425 is an
extruder, the head 424 is preferably a die.

[0117] In an embodiment a single head 424 supplies an adhesive layer 425
to the outer surface of portions of two adjacent winds of inner strip 23
and to all or substantially all of one wind of second strip 423 as they
rotate (helically) around the mandrel 21. The width of the adhesive layer
may be varied, thus, in an embodiment, the width the adhesive layer 425
should substantially cover the outer surface of the second strip 423 and
should cover approximately the same width on the outer surface of inner
strip 23, albeit on two adjacent winds of inner strip 23. The width of
the adhesive layer 425, however, may be insufficient to cover, or may
result in some excess adhesive over the amount required to completely
cover the outer surfaces of the strips 23, 423 as discussed. A strip of
composite cover material 817 having a non-porous backing is advanced
about the mandrel 21 outside of the second strip 423 and adhesive layer
425. In an embodiment, the generally non-porous backing of the composite
cover material is made of, or made predominantly of, polypropylene. In an
embodiment, the backing of the composite cover material 817 the may be
generally smooth or may have a uniform imprint thereon.

[0118] The edges of the composite cover material 817 may be offset from
the edges of the second strip 423 as they are advanced (helically) along
the mandrel 21. It is believed that the a stronger product is yielded
from having an offset between the edges of the non-porous layers, i.e.,
the composite cover material 817, the inner strip 23 and the second strip
423. An offset of between about one-quarter and three-quarters of the
width of the inner strip 23 is found to achieve acceptable results. Good
results can be achieved by having an offset of about one-third of the
width of the inner strip 23 between each of the aforementioned non-porous
layers.

[0119] Prior to the hardening and setting of the adhesive material 425, an
inwardly compressive force applies pressure to the outer surface of the
composite cover material 817, imparting inward forces on the component
parts, thus laminating the composite cover material 817, the second strip
243 and the inner strip 23 as the adhesive layer 425 sets. The continuous
roller 20 is thereby formed about the mandrel 21.

[0120] In an embodiment, the inwardly compressive force is a helical belt
system formed from rollers 28a, 28b, and a belt 28. In addition to
compressing the component parts and forming the roller, the belt 28
advances the thus-formed endless roller 20 along the mandrel 21 and
continuously rotates the endless roller, thereby also advancing the
strips 23, 423 and the composite cover material 817 around and downstream
on the mandrel 21.

[0121] The endless roller 20 may be cut by the fly-away saw 27, into
lengths after it has sufficiently set. The fly-away saw 27 may be used to
cut endless roller 20 into paint-roller sized lengths ready for
finishing, or more typically into sticks of a fixed length, such as 65'',
that may be further cut and finished into paint-rollers.

[0122] It is possible, without departing from the invention, to use more
than one head to deposit the layer of adhesive material 25 between the
composite cover material 817 and the second strip 423, and between the
second strip 423 and the inner strip 23. Regardless of the width or
number of heads, in order to produce a quality laminated continuous
roller, pressure must be applied inwardly upon the composite cover
material 817 before the layer of polypropylene is permitted to harden and
set.

[0123] A benefit of certain embodiments of the instant invention is that a
laminated roller can be produced using a narrow head and one strip and a
composite cover material with a non-porous backing, and more
specifically, with one non-porous polypropylene strip and one strip of a
composite cover material having a non-porous backing It is expected that
such a process will be easy and cost efficient to operate, and will
likely be able to produce rollers quickly. Another benefit of certain
embodiments of the present invention is that it can create a laminated
paint roller using a narrow head and one strip and a composite cover
material with a non-porous backing without the rollers being out-of-round
at its edges when they are finished and cut.

[0124] A benefit of certain embodiments of the instant invention is that
it can create a high quality laminated roller by using a single head, two
thin strips of polypropylene and a composite cover material with a
non-porous backing.

[0125]FIG. 12 shows a diagrammatic representation of a paint roller
manufacturing apparatus 900. A strip of material 23 comprising
polypropylene is wrapped helically about a mandrel 21 held on a base 22.
The mandrel may be cooled by a cooler (not shown). An adhesive 25
comprising polypropylene is applied to an outer surface of the strip 23
by applicator 24. A cover 817 is wrapped around the mandrel 21 over the
first strip 23 and the adhesive 25. A helical belt 28 driven by rollers
28a, 28b applies a compressive force on the cover material and advances
the tubular assembly 929 down the mandrel 21. A flyaway saw 27 cuts the
tubular assembly into lengths 926 that can be used, or cut and used to
produce finished paint rollers.

Compound Adhesive

[0126] In an embodiment, the adhesive 25 is a compound of polypropylene
and calcium carbonate having between 5% and 50% calcium carbonate by
weight. In an embodiment the adhesive compound comprises at least 25% but
not more than 45% calcium carbonate. In an embodiment the adhesive
compound comprises at least 25% but not more than 33% calcium carbonate.
In an embodiment, the calcium carbonate compounded with the polypropylene
to form the compound adhesive 25 should be selected and/or processed to
be relatively non-abrasive to the processing equipment.

[0127] In an embodiment, the applicator 24 applies a compound adhesive 25
formed by a twin screw extruder sufficient for compounding the calcium
carbonate with polypropylene (not shown) from a supply of polypropylene
resin in pellet form and a supply of calcium carbonate. When using a twin
screw extruder, the calcium carbonate should be relatively non-abrasive
to a extruder.

[0128] In an embodiment, the calcium carbonate compounded with the
polypropylene to form the compound adhesive 25 should be used in a
relatively fine, powdered form. In an embodiment the calcium carbonate
may have a median particle size of 3 micrometers or less. In an
embodiment, the calcium carbonate compounded with the polypropylene to
form the compound adhesive 25 may be surface treated.

[0129] The cost by weigh of calcium carbonate is expected to be lower than
the cost by weigh of polypropylene, thus the use of a compounded adhesive
25 as described will reduce the cost of manufacturing paint rollers.

[0130] The adhesive 25 made from a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight is
expected to have higher thermal conductivity that an adhesive made from
polypropylene alone. Accordingly, an adhesive 25 made from a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight is expected to cool and set faster than an adhesive
made from polypropylene alone. As a result of the higher thermal
conductivity, when the apparatus 900 is operated using an adhesive 25
made from a compound of polypropylene and calcium carbonate having
between 5% and 50% calcium carbonate by weight, it is expected that the
apparatus will operate at higher overall throughput than it would when
using an adhesive 25 comprising more than 95% polypropylene.

Compound Strip Material

[0131] In an embodiment, the strip 23 is made of a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. In an embodiment the strip 23 comprises at least 25%
but not more than 45% calcium carbonate. In an embodiment the strip 23
comprises at least 25% but not more than 33% calcium carbonate.

[0132] In an embodiment, the calcium carbonate compounded with the
polypropylene to form the strip 23 should be a relatively fine, powdered
form of calcium carbonate. In an embodiment the calcium carbonate
compounded with the polypropylene to form the strip 23 should have a
median particle size of 3 micrometers or less. In an embodiment, the
calcium carbonate compounded with the polypropylene to form the strip 23
may be surface treated.

[0133] The cost by weigh of calcium carbonate is expected to be lower than
the cost by weigh of polypropylene, thus the use of a strip 23 made from
a compound of polypropylene and calcium carbonate will reduce the cost of
manufacturing paint rollers made therewith.

[0134] The strip 23 made from a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight is
expected to have higher thermal conductivity that an adhesive made from
polypropylene alone. Because of the higher thermal conductivity using a
strip 23 made from a compound of polypropylene and calcium carbonate
having between 5% and 50% calcium carbonate by weight, rather than a
strip 23 made from more than 95% polypropylene, it is anticipated that
the adhesive 25 will set faster, and thus, apparatus 900 will operate at
higher overall throughput than it would when using a strip 23 comprising
more than 95% polypropylene.

Cover Material

[0135] In an embodiment, the cover 817 has a fabric backing and a pile
outer surface such as knitted or woven cover materials; such a fabric
backing of the cover 817 comprises interstitial pores into which adhesive
25 may flow, especially when compressed by the belt 28. In an embodiment,
the cover is made from a microfiber material; such a microfiber cover 817
also comprises interstitial pores into which adhesive 25 may flow,
especially when compressed by the belt 28.

[0136] In an embodiment, the cover 817 has a pile or microfiber outer
surface and a smooth or uniformly imprinted backing formed from
polypropylene.

[0137] In an embodiment, the cover 817 has a pile or microfiber outer
surface and a smooth or uniformly imprinted backing formed from a
compound of polypropylene and calcium carbonate having between 5% and 50%
calcium carbonate by weight. In an embodiment the cover 817 comprises at
least 25% but not more than 45% calcium carbonate. In an embodiment the
cover 817 comprises at least 25% but not more than 33% calcium carbonate.

[0138] In an embodiment, the calcium carbonate compounded with the
polypropylene to form the backing of the cover 817 should be a relatively
fine, powdered form of calcium carbonate. In an embodiment the calcium
carbonate compounded with the polypropylene to form the backing of the
cover 817 should have a median particle size of 3 micrometers or less. In
an embodiment, the calcium carbonate compounded with the polypropylene to
form the backing of the cover 817 may be surface treated.

[0139] The cost by weigh of calcium carbonate is expected to be lower than
the cost by weigh of polypropylene, thus the use of the backing of the
cover 817 made from a compound of polypropylene and calcium carbonate
will reduce the cost of manufacturing paint rollers made therewith.

[0140] The backing of the cover 817 made from a compound of polypropylene
and calcium carbonate having between 5% and 50% calcium carbonate by
weight is expected to have higher thermal conductivity that an adhesive
made from polypropylene alone. Because of the higher thermal conductivity
using a cover 817 having a backing made from a compound of polypropylene
and calcium carbonate having between 5% and 50% calcium carbonate by
weight, rather than a backing made from more than 95% polypropylene, it
is anticipated that the adhesive 25 will set faster, and thus, apparatus
900 will operate at higher overall throughput than it would when using a
cover 817 having a backing comprising more than 95% polypropylene.

Use of Compounded Materials

[0141] Apparatus 900 may be operated according to the present invention
using an adhesive 25 made of a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight; using a
strip 23 made of a compound of polypropylene and calcium carbonate having
between 5% and 50% calcium carbonate by weight; and/or using a cover 817
having a backing made of a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight. When
more than one component is made of a compound of polypropylene and
calcium carbonate having between 5% and 50% calcium carbonate by weight,
the percentage of calcium carbonate used in the compound forming the
adhesive 25, the strip 23 and the cover 817 backing may be the same, or
may differ from one-another.

[0142] When compounding of polypropylene and calcium carbonate in any
compound of between 5% and 50% calcium carbonate by weight, the calcium
carbonate is not expected to melt. As discussed above, the resulting
compounds are expected to have higher thermal conductivity. Variation in
the amount of calcium carbonate are within the scope of the invention,
and thus, it will be apparent to one of skill in the art that to some
degree thermal conductivity can be controlled, or a desired thermal
conductivity or range of thermal conductivity can be achieved by varying
the percentage of calcium carbonate in the compound.

[0143] The compounds of polypropylene and calcium carbonate used in the
adhesive 25, strip 23 and/or cover 817 are expected to have achieve other
characteristics that, when compared to using polypropylene alone, are
expected to include increased stiffness. Increased stiffness may give a
paint roller a firmer or stiffer feel, which may improve its performance
as a paint roller. Moreover, in many cases, stiffer or firmer paint
rollers are sold at a higher price. It will be apparent to one of skill
in the art that to some degree, stiffness can be controlled, or a desired
stiffness or range of stiffness can be achieved by varying the percentage
of calcium carbonate in the compound.

[0144]FIG. 4 shows an apparatus 801B for forming the composite paint
roller cover 817 having a compound backing. The roller 880 is urged
toward the frame 890 by a spring, by gravity or by other means that will
be apparent to persons skilled in the art. A layer of compound adhesive
820 is dispensed by an applicator 809 onto a roller 880, and runs between
the roller 880 and a frame 890, such as a tenter frame, or between the
roller 880 and another roller (not shown). The layer of compound adhesive
820 dispensed onto roller 880 may be between 0.010'' and 0.020''. In an
embodiment, the compound adhesive 820 is a compound of polypropylene and
calcium carbonate having between 5% and 50% calcium carbonate by weight.
In an embodiment the adhesive compound comprises at least 25% but not
more than 45% calcium carbonate. In an embodiment the adhesive compound
comprises at least 25% but not more than 33% calcium carbonate. The
calcium carbonate should be relatively non-abrasive to the processing
machinery.

[0145] The cover material 802 is advanced along the frame 890 with its
pile side down, and moved beneath the roller 880. The cover material 802
may have a pile side and a fabric backing--the fabric backing being
porous and having interstitial spaces sufficient to permit penetration of
the compound adhesive 820. As the cover material 802 and the layer of
compound adhesive 820 pass between the roller 880 and the surface of the
frame 890 they are urged together. The roller-side of the compound
adhesive 820 may be smoothed or uniformly imprinted (e.g., embossed) by
the roller 880 as it passed underneath, thus forming a uniform or smooth
adhesive layer surface 851.

[0146] In an embodiment, the roller 880 applies a compressive force to
urge the compound adhesive 820 towards the cover material 802. In an
embodiment, the compressive force is sufficient to force the compound
adhesive 820 into the interstitial spaces within the fabric backing of
the cover material 802. The resulting composite sheet material 815 may be
cut by a cutter 816 to trim away any excess materials, and thus to form
the compound composite cover material 817 with a non-porous backing.

[0147] In an embodiment, the roller 880 may be heated or cooled.

[0148] In an embodiment, the apparatus comprises an applicator 809 that
applies a compound adhesive 820 formed by a twin screw extruder
sufficient for compounding calcium carbonate with polypropylene (not
shown) from a supply of polypropylene resin in pellet form and a supply
of calcium carbonate. The calcium carbonate should be relatively
non-abrasive to the twin screw extruder.

[0149] The positioning and angular orientation of the applicator 809 may
be varied. In an embodiment, the applicator is angled between 30 degrees
and 60 degrees from vertical and positioned within inches of the middle
of the roller 880. In another embodiment the applicator 809 is within 30
degrees (+/-) of vertical, and is positioned to dispense adhesive such
that the adhesive layer 820 first makes contact on the upper half of the
roller 880. In yet another embodiment, the applicator 809 is within 30
degrees (+/-) of horizontal and is positioned to dispense adhesive such
that the adhesive layer 820 first makes contact on the lower half of the
roller 880. Variations in the angular orientation of the applicator 809,
and its distance from and orientation around the roller are within the
scope of the invention, and will be apparent to one skilled in the art.

[0150]FIG. 14 shows a paint roller manufacturing apparatus 410. A strip
of material 23 comprising polypropylene is wrapped helically about a
mandrel 21 held on a base 22. The mandrel may be cooled by a cooler (not
shown). A second strip of material 423 comprising polypropylene is
wrapped helically about the first strip 23. An adhesive 425 comprising
polypropylene is applied to an outer surface of the strips 23, 423 by
applicator 424. A cover 817 is also helically wrapped around the mandrel
21 over the strips 23, 423 and the adhesive 425. A helical belt 28 driven
by rollers 28a, 28b applies a compressive force on the cover material and
advances the tubular assembly 310 down the mandrel 21. A flyaway saw 27
may cut the tubular assembly 20 into lengths (not shown) that can be
used, or further cut and used to produce finished paint rollers.

[0151] In an embodiment, the applicator 424 applies a compound adhesive
425 formed by a twin screw extruder sufficient for compounding the
calcium carbonate with polypropylene (not shown) from a supply of
polypropylene resin in pellet form and a supply of calcium carbonate.
When using a twin screw extruder, the calcium carbonate should be
relatively non-abrasive to a extruder.

[0152] Apparatus 410 may be operated according to the present invention
using an adhesive 425 made of a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight; using a
strip 23 made of a compound of polypropylene and calcium carbonate having
between 5% and 50% calcium carbonate by weight; using a second strip 423
made of a compound of polypropylene and calcium carbonate having between
5% and 50% calcium carbonate by weight; and/or using a cover 817 having a
backing made of a compound of polypropylene and calcium carbonate having
between 5% and 50% calcium carbonate by weight. When more than one
component is made of a compound of polypropylene and calcium carbonate
having between 5% and 50% calcium carbonate by weight, the percentage of
calcium carbonate used in the compound forming the adhesive 425, the
strip 23, the second strip 423 and the cover 817 backing may be the same,
or may differ from one-another.

[0153] Variation in the amount of calcium carbonate are within the scope
of the invention, and thus, it will be apparent to one of skill in the
art that to some degree thermal conductivity can be controlled, or a
desired thermal conductivity or range of thermal conductivity can be
achieved by varying the percentage of calcium carbonate in one or more of
the compounds. It will be apparent to one of skill in the art that to
some degree, stiffness can be controlled, or a desired stiffness or range
of stiffness can be achieved by varying the percentage of calcium
carbonate in these compounds as well.

[0154]FIG. 15 shows a paint roller manufacturing apparatus 400. A strip
of material 448 comprising polypropylene is wrapped helically about a
mandrel 440 held on a base 450. The mandrel may be cooled by a cooler
(not shown). A second strip of material 445 comprising polypropylene is
wrapped helically about the first strip 448. The heaters 460, 455 which
may employ heating elements or heat by open flame, heat the outer surface
(vis-a-vis the wrapping about the mandrel) of strips 448, 445
respectively. The heat produced by the heaters 460 is sufficient to cause
the outer surface of the strips 448, 445 to become tacky, or to liquefy,
or to become molten. (Although shown diagrammatically at a distance from
the mandrel, in an embodiment, the heaters 460, 455 should be placed as
close as practicable to the point where the strips 448, 445 contact the
mandrel.) A cover 415 is also helically wrapped around the mandrel 440
over the outer surface of the second strip 445. A helical belt drive 420
applies an inwardly compressive force on the cover material 415 and
advances the assembly down the mandrel 440. A flyaway saw 405 may cut the
assembly into lengths (not shown) that can be used, or further cut and
used to produce finished paint rollers.

[0155] Apparatus 400 may be operated according to the present invention
using a strip 448 made of a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight; using a
second strip 445 made of a compound of polypropylene and calcium
carbonate having between 5% and 50% calcium carbonate by weight; and/or
using a cover 415 having a backing made of a compound of polypropylene
and calcium carbonate having between 5% and 50% calcium carbonate by
weight. When more than one component is made of a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight, the percentage of calcium carbonate used in the
compound forming the strips 448, 445 and the cover 415 backing may be the
same, or may differ from one-another.

[0156] Variation in the amount of calcium carbonate are within the scope
of the invention, and thus, it will be apparent to one of skill in the
art that to some degree thermal conductivity can be controlled, or a
desired thermal conductivity or range of thermal conductivity can be
achieved by varying the percentage of calcium carbonate in one or more of
the compounds. It will be apparent to one of skill in the art that to
some degree, stiffness can be controlled, or a desired stiffness or range
of stiffness can be achieved by varying the percentage of calcium
carbonate in these compounds as well.

[0157]FIG. 16 shows an apparatus 500 suitable for making paint rollers
with a preformed core. The apparatus 500 comprises a rotating mandrel
510, a carriage 560 running on a stationary track 570 and supporting a
cover material guide 550, and a heater 530. A preformed core 540
comprising polypropylene is placed about the mandrel 510. The heater 530
is activated, thereby heat softening the outer surface of the preformed
core in an amount sufficient to bond to the backing of the cover 520. The
cover 520 is wrapped helically about the core by the rotation of the
mandrel and the movement of the carriage 560. The rotation of the mandrel
510 and the movement of the carriage 560 are such that the cover 520 is
wrapped about substantially all of the preformed core 540.

[0158] Apparatus 500 may be operated according to the present invention
using a preformed core 540 made of a compound of polypropylene and
calcium carbonate having between 5% and 50% calcium carbonate by weight;
and/or using a cover 520 having a backing made of a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. When more than one component is made of a compound
of polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight, the percentage of calcium carbonate used in the
compound forming the core 540 and the cover 520 backing may be the same,
or may differ from one-another.

[0159] Variation in the amount of calcium carbonate are within the scope
of the invention, and thus, it will be apparent to one of skill in the
art that to some degree thermal conductivity can be controlled, or a
desired thermal conductivity or range of thermal conductivity can be
achieved by varying the percentage of calcium carbonate in one or more of
the compounds. It will be apparent to one of skill in the art that to
some degree, stiffness can be controlled, or a desired stiffness or range
of stiffness can be achieved by varying the percentage of calcium
carbonate in these compounds as well.

[0160] It is possible, without departing from the invention, to use a
compound of polypropylene and calcium carbonate having between 5% and 50%
calcium carbonate by weight in lieu of polypropylene in making paint
rollers. In light of this disclosure, other methods for the manufacture
of the same will be apparent to persons of skill in the art.

[0161] Benefits of certain embodiments of the instant invention include:
control of thermal conductivity in the component materials leading to
faster throughput and/or faster set times; and control of material
characteristics such as stiffness for manufacture of harder, more
expensive paint rollers.

[0162] The above embodiments and preferences are illustrative of the
present invention. It is neither necessary, nor intended for this patent
to outline or define every possible combination or embodiment. The
inventor has disclosed sufficient information to permit one skilled in
the art to practice at least one embodiment of the invention, and has
disclosed the ways the inventor now believes are the best ways to
practice the invention. The above description and drawings are merely
illustrative of the present invention and that changes in components,
structure and procedure are possible without departing from the scope of
the present invention as defined in the following claims.

Illustrative Embodiments Shown in the Figures of U.S. Patent Application
Ser. No. 12/463,876

[0163] In one embodiment, the invention is a method of making a paint
roller. A strip of material is helically wound around a mandrel so as to
form a helically wound strip. The strip is formed from a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. The wound strip is advanced along the mandrel. A
layer of adhesive is applied onto an outer surface of the wound strip. A
strip of cover material then is helically wrapped about the wound strip
and over the layer of adhesive, thereby bonding the strip of cover
material to the wound strip for forming the paint roller.

[0164] In another embodiment, the invention is method of making a paint
roller. A strip of material is helically wound around a mandrel so as to
form a helically wound strip. The wound strip is advanced along the
mandrel. An adhesive is compounded from polypropylene and calcium
carbonate. The compound comprises between 5% and 50% calcium carbonate by
weight. The layer of adhesive is applied onto an outer surface of the
wound strip. A strip of cover material then is helically wrapped about
the wound strip and over the layer of adhesive, thereby bonding the strip
of cover material to the wound strip for forming the paint roller.

[0165] In another embodiment, the invention is method of making a paint
roller. A strip of material helically wound around a mandrel so as to
form a helically wound strip. The strip is formed from a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. The wound strip is advanced along the mandrel. An
adhesive is compounded from polypropylene and calcium carbonate. The
compound comprises between 5% and 50% calcium carbonate by weight. The
layer of adhesive is applied onto an outer surface of the wound strip. A
strip of cover material then is helically wrapped about the wound strip
and over the layer of adhesive, thereby bonding the strip of cover
material to the wound strip for forming the paint roller.

[0166] In another embodiment, the invention is a method for continuously
producing a multi-strip laminate paint roller. An inner strip and an
outer strip of material is helically advanced about a mandrel in offset
relation. At least one of the strips is formed from a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. A layer of adhesive is applied between the two
strips and on the outer surface of the outer strip. Prior to permitting
the layer of liquid polypropylene to harden and set, a cover is wrapped
around the outer strip and a compressing force is applied upon the cover
urging the cover and the two strips toward the mandrel, thereby creating
the continuous laminated paint roller.

[0167] In another embodiment, the invention is a method for continuously
producing a multi-strip laminate paint roller. An inner strip and an
outer strip of material is helically advanced about a mandrel in offset
relation. An adhesive material is compounded from polypropylene and
calcium carbonate, the compound comprising between 5% and 50% calcium
carbonate by weight. The adhesive material is applied between the two
strips and on the outer surface of the outer strip. Prior to permitting
the adhesive material to harden and set, a cover is wrapped around the
outer strip and a compressing force is applied upon the cover urging the
cover and the two strips toward the mandrel, thereby creating the
continuous laminated paint roller.

[0168] In another embodiment, the invention is a method for continuously
producing a multi-strip laminate paint roller. An inner strip and an
outer strip of material is helically advanced about a mandrel in offset
relation, at least one of the strips being formed from a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. An adhesive material is compounded from
polypropylene and calcium carbonate. The compound comprises between 5%
and 50% calcium carbonate by weight. The adhesive material is applied
between the two strips and on the outer surface of the outer strip. Prior
to permitting the layer of liquid polypropylene to harden and set, a
cover is wrapped around the outer strip and a compressing force is
applied upon the cover urging the cover and the two strips toward the
mandrel, thereby creating the continuous laminated paint roller.

[0169] In another embodiment, the invention is a method of making a
composite cover material. A first width of pile material is advanced. The
pile material has a pile side and a fabric backing, wherein the fabric
backing is porous, having interstitial spaces or gaps. An adhesive is
compounded from polypropylene and calcium carbonate. The compound
comprises between 5% and 50% calcium carbonate by weight. A layer of the
adhesive is applied to the fabric backing of the pile material. The
adhesive layer is allowed to set to form a composite sheet material
having a pile side and a non-porous backing. The composite sheet material
is longitudinally cut to form one or more strips of composite cover
material in a second width. The formed composite cover material has an
inner surface and an outer surface, the outer surface comprising a pile,
and the inner surface comprising a non-porous layer bonded thereto.

[0170] In another embodiment, the invention is a method of making a paint
roller having one or more materials making up its core. An adhesive
material is compounded from polypropylene and calcium carbonate. The
compound comprises between 5% and 50% calcium carbonate by weight. The
adhesive material is applied between a cover material and one or more
materials making up the paint roller core. The adhesive material is
permitted to harden and set, thereby creating the paint roller.

[0171] In another embodiment, the invention is a method of making a
laminated paint roller. A strip comprising polypropylene is helically
wound around a mandrel so as to form a helically wound strip, the strip
having an outer surface. The wound strip is helically advanced along the
mandrel. A layer of adhesive comprising polypropylene is applied onto the
outer surface of the wound strip. A strip of composite cover material is
then wrapped about the wound strip and over the layer of adhesive. The
composite cover material is formed by method comprising the following
steps. A width of porous pile material is provided having a pile side and
an fabric underside. The width of pile material is advanced with the
fabric underside facing up. A backing layer is compounded from
polypropylene and calcium carbonate, the compound comprising between 5%
and 50% calcium carbonate by weight. The backing layer is applied on the
fabric underside of the advancing width of pile material so that the
layer has one side that is in contact with the fabric underside of the
advancing material and an other side that is not in contact with the
advancing pile material, the layer being in molten form when it is
applied. A compressive force is applied to the other side of the layer
before the layer hardens and sets, to smooth the other side of the layer
of polypropylene, and to urge the layer and the fabric underside of the
pile material together, thereby forming a composite material having a
smooth or uniformly imprinted non-porous side and a pile side, and
wherein the pile is held fast on the composite material. The width of
composite material is cut into a strip once the backing layer is no
longer in molten form, thereby forming a composite cover material having
an inner surface comprising a smooth or uniformly imprinted non-porous
polypropylene side and a pile side. The composite cover material produced
by the method described above is then used to form a laminated pain
roller. A compressive force is applied from without the composite cover
material to urge the composite cover material, the layer of adhesive and
strip of non-porous polypropylene material together, thereby laminating
the smooth inner surface of the composite cover material to the outer
surface of the non-porous polypropylene strip.

[0172] In another embodiment, the invention is a method of making a
laminated paint roller. An inner strip of thermoplastic material is
helically around a mandrel so as to form a helically wound inner strip,
the inner strip having an outer surface. A second strip of thermoplastic
material is helically wound around a mandrel in offset relation to the
inner strip, so as to form a helically wound second strip, the second
strip having an inner surface and an outer surface. The wound inner and
second strips are advanced along the mandrel. An adhesive is compounded
from polypropylene and calcium carbonate, the compound comprising between
5% and 50% calcium carbonate by weight. A layer of the adhesive is
applied onto the outer surface of the wound inner strip and the outer
surface of the wound second strip. A strip of composite cover material is
then wrapped about the wound second strip and over the layer of adhesive
applied to the wound second strip. The composite cover material has an
inner surface and an outer surface, the outer surface comprising a pile
fabric, and the inner surface comprising a smooth generally non-porous
backing comprising polypropylene. A compressive force is then applied
from without the composite cover material to urge the composite cover
material, the layer of adhesive and inner and second strips together,
thereby laminating the inner surface of the composite cover material to
the outer surface of the second strip and laminating the inner surface of
the second strip to the outer surface of the inner strip.

[0173] In another embodiment, the invention is a method for continuously
producing a multi-strip laminate paint roller. An inner strip and an
outer strip of material is helically advanced about a mandrel in offset
relation. At least one of the strips is formed from a compound of
polypropylene and calcium carbonate having between 5% and 50% calcium
carbonate by weight. The inner strip and the outer strip have an outer
surface facing away from the mandrel. The outer surface of the inner and
outer strips is heated to cause a layer of the outer surface of the
strips to become liquefied. Prior to permitting the liquefied layers to
harden and set, a cover around is wrapped around the outer strip and a
compressing force is applied upon the cover urging the cover and the two
strips toward the mandrel, thereby creating the continuous laminated
paint roller.

[0174] In another embodiment, the invention is a cold core method of
making a paint roller from a cold, hard, preformed hollow core of
thermoplastic material of a predetermined length in which the cold hard
hollow core and its associated cover are forged together to form a single
unitary body. A cold hard hollow core is provided. The cold hard hollow
core is formed from a compound of polypropylene and calcium carbonate
having between 5% and 50% calcium carbonate by weight. A mandrel having
an external diameter is provided. The mandrel slidably receives and makes
contact with the cold hard hollow core. The cold hard hollow core is
rotated. The exterior surface of the cold hard hollow thermoplastic
rotating core is heated, by application of a single source of heat, to a
temperature high enough to cause subsequently applied cover to adhere to
said exterior surface. A cover is then to the heated exterior surface of
the cold hard hollow thermoplastic core, thereby bonding the cover to the
heated exterior surface thereof, and forming a paint roller.

Further Observations

[0175] In experimenting with various ratios and materials, several further
observations have been made, and the inventions of such further
observations and additional embodiments are hereinafter presented, in
addition to those discussed above. Polypropylene identified as 3462-US,
4920WZ-US and 6823MZ-US from Total Petrochemicals of Houston, Tex. was
used for experimentation. MFI reported herein for the polypropylene resin
is as understood from Total Petrochemicals literature.

Calcium Carbonate

[0176] The use of non-refined calcium carbonate in combination with
polypropylene, e.g., calcium carbonate that has not been surface treated,
adds strength to the resulting paint roller product when compared to a
combination of refined calcium carbonate in combination with
polypropylene. Thus, in an embodiment, the calcium carbonate compounded
with the polypropylene to form the compound adhesive 25 (FIG. 12) may be
a non-refined calcium carbonate. In an embodiment, the non-refined
calcium carbonate is used in a relatively fine, powdered form. In an
embodiment the calcium carbonate may have a median particle size of 3
micrometers or less.

[0177] In an embodiment, a twin screw extruder (not shown) may be used to
compound non-refined calcium carbonate and polypropylene together to form
the compound adhesive 25. The twin screw extruder may accept a supply of
polypropylene resin in pellet form and a separate supply of calcium
carbonate.

Ratio and Composition of Compound Adhesive

[0178] Experimentation was performed concerning the ratio of calcium
carbonate--a ratio earlier thought to be preferred between 5% and 50%
calcium carbonate by weight. As discussed above, the cost by weigh of
calcium carbonate is generally lower than the cost by weigh of
polypropylene, thus, the raw material cost of a compounded adhesive will
be reduced as the ratio of calcium carbonate rises. Typically, today, the
cost of polypropylene resin may be $0.64 per pound, while the cost of
appropriate calcium carbonate may be $0.09 per pound. Using those typical
costs, the raw materials required to make a compounded adhesive
comprising 5% calcium carbonate by weight is approximately $0.6125 per
pound; the raw materials required to make a compounded adhesive
comprising 50% calcium carbonate by weight is approximately $0.365 per
pound; and the raw materials required to make a compounded adhesive
comprising 60% calcium carbonate by weight is approximately $0.31 per
pound. While the process of compounding the materials itself has a cost,
the large factors in savings are: (i) the disparity between the cost of
the polypropylene resin and the calcium carbonate; and (ii) the
percentages of calcium carbonate that can be used.

[0179] Experimentation was performed and acceptable results were found
using a compounded adhesive 25 (see FIG. 12) made from polypropylene
resin with approximately 60% calcium carbonate by weight. In an
embodiment, adhesive 25 is a compound of polypropylene and calcium
carbonate having between 50% and 66% calcium carbonate by weight. In an
embodiment an adhesive compound 25 comprises at least 55% but not more
than 65% calcium carbonate. In an embodiment an adhesive compound 25 is a
compound of polypropylene and calcium carbonate having approximately 60%
calcium carbonate by weight.

[0180] Experimentation was performed and acceptable results were found
using a compounded adhesive 425 (see FIG. 14) made from polypropylene
resin with approximately 56% calcium carbonate by weight. In an
embodiment, an adhesive 425 is a compound of polypropylene and calcium
carbonate having at least 50%, but less than 60% calcium carbonate by
weight. In an embodiment an adhesive compound 425 is a compound of
polypropylene and calcium carbonate having approximately 56% calcium
carbonate by weight.

[0181] Polypropylene resin 6823MZ-US in pellet form used to create
adhesive first used for the further testing had a melt flow index ("MFI")
of approximately 32. For the further testing, the 32 MFI resin was
compounded with a 60% mixture of calcium carbonate to form the compound
adhesive 25. The resulting compound adhesive 25 had an MFI of
approximately 14.4. Although the compound adhesive could be extruded
through applicator 24, the low MFI appeared to cause the extruded to
struggle, and the extruded material was highly viscous. The paint rollers
resulting from the foregoing compound appeared to be substantially
stronger when non-refined calcium carbonate was used rather than surface
treated calcium carbonate. When the same 32 MFI resin was compounded with
the same 60% mixture of calcium carbonate to form the compound adhesive
425 (see FIG. 14), it appeared that the MFI of the compound adhesive 425
was too high to permit a smooth flow from the applicator 424.

[0182] Polypropylene resin 4920WZ-US was tried. Polypropylene resin
4920WZ-US in pellet form used to create adhesive next used for the
further testing had a melt flow index ("MFI") of approximately 105. For
the next test, the 105 MFI resin was compounded with a 60% mixture of
calcium carbonate to form the compound adhesive 25. The resulting
compound adhesive 25 had an MFI of approximately 28.8. Using the 105 MFI
resin, the compound adhesive 25 was extruded through applicator 24
without substantial stress on the extruder as the compounded adhesive 25
was of appropriate viscosity for use with the applicator 24. Again, the
paint rollers resulting from the foregoing compound was substantially
stronger when non-refined calcium carbonate was used rather than surface
treated calcium carbonate. When the same 105 MFI resin was compounded
with the same 60% mixture of calcium carbonate to form the compound
adhesive 425 (see FIG. 14), it again appeared that the MFI was too high
to permit a smooth flow from the applicator 424.

[0183] As the vendor did not have polypropylene resin available with an
MFI higher than 105, for the following test, the 105 MFI resin was
compounded with a 56% mixture of calcium carbonate to form the compound
adhesive 425. The resulting compound adhesive 425 had an MFI of
approximately 32. Using the 105 MFI resin, the compound adhesive 425 was
extruded through applicator 424 without substantial stress on the
extruder as the compounded adhesive 425 was of appropriate viscosity for
use with the applicator 424. As before, the paint rollers resulting from
the foregoing compound appeared to be substantially stronger when
non-refined calcium carbonate was used rather than surface treated
calcium carbonate. As an alternative to reducing ratio of calcium
carbonate to 56%, the use of a polypropylene resin having a higher MFI,
such as an MFI of approximately 120, with 60% calcium carbonate would
have achieved acceptable results.

Composition of Strips

[0184] As with composite adhesives 25, 425, strip material 23, 423, 445,
448 can be manufactured using a compound of polypropylene and calcium
carbonate. In an embodiment, a strip 23, 423, 445, 448 is cut lengthwise
from a sheet material (not shown) that is manufactured using a compound
of polypropylene and calcium carbonate. In an embodiment, the thickness
of the sheet material is determined by successive rollers. Because
rollers are used to control thickness, the MFI of the
polypropylene/calcium carbonate compound may be substantially lower than
that of the MFI required for use a compound adhesives 25, 425. In an
embodiment, 4.1 MFI polypropylene resin 3462-US is compounded with
approximate 60% by weight of calcium carbonate. The resulting
polypropylene/calcium carbonate compound, having an MFI of approximately
2, can be run through successive rollers to reach a desired thickness.
Almost any desired strip thickness can be attained. In an embodiment, a
sheet of polypropylene/calcium carbonate compound material having
thickness of approximately 10 mil, 15 mil, 20 mil or 25 mil can be cut
longitudinally into one or more strip 23, 445, 448.

[0185] In an embodiment, the calcium carbonate used in manufacturing sheet
material which can be cut into strips is non-refined calcium carbonate.

Composite Cover Material

[0186] Returning to FIG. 4, an apparatus 801B is shown for forming the
composite paint roller cover 817 having a compound backing A layer of
compound adhesive 820 is dispensed by an applicator 809. The layer of
compound adhesive 820 dispensed may be dispensed onto roller 880 or
directly onto cover material 802. In an embodiment, the layer of compound
adhesive 820 is between 0.010'' and 0.020''. In an embodiment, the
compound adhesive 820 is a compound of polypropylene and calcium
carbonate having at least 50%, and not more than 66% calcium carbonate by
weight. The MFI of polypropylene/calcium carbonate compound the may be
varied by changing using a polypropylene resin having a higher or lower
MFI, as well as by varying the ratio of calcium carbonate. Using
polypropylene resin having a higher MFI will cause the
polypropylene/calcium carbonate compound to have a higher MFI when using
the same ratio of calcium carbonate. Similarly, the MFI of the resulting
compound can be lowered by reducing the percentage of calcium carbonate
used in the polypropylene/calcium carbonate compound. In view of the
foregoing, it will be apparent to one of skill in the art how to the MFI
of polypropylene/calcium carbonate compound layer 820 can be varied so as
to permit it to be dispensed appropriately by an applicator 809.

[0187] In an embodiment, the cover material 802 has a pile side and a
fabric backing--the fabric backing being porous and having interstitial
spaces sufficient to permit penetration of compound adhesive 820. In an
embodiment, the compound adhesive 820 has an MFI higher than 2. In an
embodiment, the compound adhesive 820 has an MFI between 14 and 105. In
an embodiment, an MFI of in or around the mid 70's is desired to permit
the compound 820 to properly permeate the fabric backing of the cover
material 802. To obtain compound adhesive 820 having an MFI in or around
the mid-70's 105 MFI polypropylene resin is compounded with 25% calcium
carbonate by weight.

[0188] In an embodiment, the apparatus comprises an applicator 809 that
applies a compound adhesive 820 formed by a twin screw extruder
sufficient for compounding calcium carbonate with polypropylene (not
shown) from a supply of polypropylene resin in pellet form and a supply
of calcium carbonate to produce a compound that includes at least 50%
calcium carbonate by weight.

Illustrative Paint Rollers

[0189] Returning to FIG. 12, in an embodiment, a strip 23 comprises
polypropylene, and has a thickness of between 10 mil and 40 mil. In an
embodiment, the strip 23 is approximately 10 mil, 15 mil, 20 mil or 25
mil thick. In an embodiment, the strip 23 may be of another suitable
thickness.

[0190] In an embodiment, the strip 23 is made from a polypropylene/calcium
carbonate compound comprising at least 50%, but not more than 66% calcium
carbonate by weight. In an embodiment, the strip 23 is made from a
polypropylene/calcium carbonate compound comprising approximately 60%
calcium carbonate by weight. The strip 23 made from a
polypropylene/calcium carbonate compound comprising at least 50% calcium
carbonate by weight, is expected to have higher thermal conductivity than
a strip made from polypropylene alone, or than a strip made from a
polypropylene/calcium carbonate compound comprising less than 50% calcium
carbonate by weight. Because of the higher thermal conductivity using a
strip 23 made from a compound of polypropylene and calcium carbonate
comprising at least 50% calcium carbonate by weight, it is anticipated
that the adhesive 25 will set faster, and thus, apparatus 900 will
operate at higher overall throughput than it would when using a strip 23
comprising more than 50% polypropylene.

[0191] In an embodiment, adhesive 25 comprises polypropylene, and is
applied in a layer having a thickness of between 10 mil and 40 mil. In an
embodiment, the layer of adhesive 25 is approximately 10 mil, 15 mil, 20
mil or 25 mil thick. In an embodiment, the layer of adhesive 25 is
another suitable thickness.

[0192] In an embodiment, the adhesive 25 is made from a
polypropylene/calcium carbonate compound comprising at least 50%, but not
more than 66% calcium carbonate by weight. In an embodiment, the adhesive
25 is made from a polypropylene/calcium carbonate compound comprising
approximately 60% calcium carbonate by weight. The adhesive 25 made from
a polypropylene/calcium carbonate compound comprising at least 50%
calcium carbonate by weight, is expected to have higher thermal
conductivity than an adhesive made from polypropylene alone, or than an
adhesive made from a polypropylene/calcium carbonate compound comprising
less than 50% calcium carbonate by weight. Because of the higher thermal
conductivity using an adhesive 25 made from a compound of polypropylene
and calcium carbonate comprising at least 50% calcium carbonate by
weight, it is anticipated that it will set faster, and thus, apparatus
900 will operate at higher overall throughput than it would when using an
adhesive 25 comprising more than 50% polypropylene.

[0193] In an embodiment, the backing of composite cover 817 comprises
polypropylene, and the backing comprising polypropylene is in a layer
having a thickness of between 10 mil and 40 mil. In an embodiment, the
backing layer of the composite cover material 817 is approximately 10
mil, 15 mil, 20 mil or 25 mil thick. In an embodiment, the backing of the
composite cover material 817 is another suitable thickness.

[0194] In an embodiment, the backing of the composite cover material 817
is formed from a polypropylene/calcium carbonate compound comprising at
least 50%, but not more than 66% calcium carbonate by weight. In an
embodiment, the backing of the composite cover material 817 is formed
from a polypropylene/calcium carbonate compound comprising approximately
60% calcium carbonate by weight. The backing of the composite cover
material 817 formed from a polypropylene/calcium carbonate compound
comprising at least 50% calcium carbonate by weight, is expected to have
higher thermal conductivity than a backing made from polypropylene alone,
or than a backing made from a polypropylene/calcium carbonate compound
comprising less than 50% calcium carbonate by weight. Because of the
higher thermal conductivity using a composite cover material 817 having a
backing formed from a compound of polypropylene and calcium carbonate
comprising at least 50% calcium carbonate by weight, it is anticipated
that the adhesive 25 will set faster, and thus, apparatus 900 will
operate at higher overall throughput than it would when using a composite
cover material 817 having a backing formed from a compound of
polypropylene and calcium carbonate comprising more than 50%
polypropylene.

[0195] The following tables presents illustrative paint rollers that will
be used in the discussion below.

[0196] The following table presents illustrative paint rollers that can be
formed using the invention disclosed herein. The "Cover" column refers to
the cover material 817 used, the "Adhesive" column refers to the adhesive
25 used and the "Strip" column refers to the strip 23 used in the
example. For each column, the entry reflects the thickness in mil, and
the percentage of calcium carbonate (by weight) compounded with
polypropylene to form the component. The thickness in mil for the "Cover"
column reflects the thickness of the layer 25 used to form the composite
cover material 817--the "Cover" column entries showing a thickness of 0
reflect the use of a cover material rather than a composite cover
material.

[0197] Example A1 and B1, each make paint rollers of the same thickness,
however, the characteristics of the paint roller B1 are substantially
improved when compared to those of A1. The B1 paint roller feels firmer
and is of higher quality than the A1 paint roller. Moreover, the mil
thick B1 paint roller uses only 40% of the polypropylene used to
manufacture the A1 paint roller (excluding any polypropylene in the cover
material).

[0198] Similarly, Example A2 and B2, each make paint rollers of the same
thickness, however, the characteristics of the paint roller B2 are
substantially improved when compared to those of A2. The B2 paint roller
feels firmer and is of higher quality than the A2 paint roller. Moreover,
the 40 mil thick B2 paint roller uses only 55% of the polypropylene used
to make the A2 paint roller (excluding any polypropylene in the cover
material). In fact, the B1 paint roller compares favorably to the A2
paint roller while using only as much as 30% as much polypropylene.

[0199] Notably the B3 paint roller is the most superior of all of these
example rollers, and it uses less than half as much polypropylene as the
A2 roller, and just over half as much as the A1 roller.

[0200] Many other variations are possible. For example, it is not
necessary to use both a compound adhesive and a strip formed from
compounding polypropylene and calcium carbonate. In addition, it is not
necessary to use a composite cover material formed from a compound of
polypropylene/calcium carbonate. The use of (i) a compound strip, (ii)
compound adhesive or (ii) composite cover material formed from a compound
of polypropylene/calcium carbonate, will each produce a stronger roller,
with less polypropylene, than the use of same component made from
non-compound polypropylene.

[0201] Returning now to FIG. 14, in an embodiment, strips 23, 423 comprise
polypropylene, and each have a thickness of between 10 mil and 40 mil. In
an embodiment, strips 23, 423 are each approximately 10 mil, 15 mil, 20
mil or 25 mil thick. In an embodiment, strips 23, 423 may be of another
suitable thickness. It is not necessary that each of the strips 23, 423
are the same thickness.

[0202] In an embodiment, at least one strip 23, 423 is made from a
polypropylene/calcium carbonate compound comprising at least 50%, but not
more than 66% calcium carbonate by weight. In an embodiment, at least one
strip 23, 423 is made from a polypropylene/calcium carbonate compound
comprising approximately 60% calcium carbonate by weight. A strip 23, 423
made from a polypropylene/calcium carbonate compound comprising at least
50% calcium carbonate by weight, is expected to have higher thermal
conductivity than a strip made from polypropylene alone, or than a strip
made from a polypropylene/calcium carbonate compound comprising less than
50% calcium carbonate by weight. Because of the higher thermal
conductivity using at least one strip 23, 423 made from a compound of
polypropylene and calcium carbonate comprising at least 50% calcium
carbonate by weight, it is anticipated that the adhesive 425 will set
faster, and thus, apparatus 410 will operate at higher overall throughput
than it would when using strips 23, 423 comprising more than 50%
polypropylene.

[0203] In an embodiment, adhesive 425 comprises polypropylene, and is
applied in a layer having a thickness of between 10 mil and 40 mil. In an
embodiment, the layer of adhesive 425 is approximately 10 mil, 15 mil, 20
mil or 25 mil thick. In an embodiment, the layer of adhesive 425 is
another suitable thickness.

[0204] In an embodiment, the adhesive 425 is made from a
polypropylene/calcium carbonate compound comprising at least 50%, but not
more than 66% calcium carbonate by weight. In an embodiment, the adhesive
425 is made from a polypropylene/calcium carbonate compound comprising
approximately 60% calcium carbonate by weight. The adhesive 425 made from
a polypropylene/calcium carbonate compound comprising at least 50%
calcium carbonate by weight, is expected to have higher thermal
conductivity than an adhesive made from polypropylene alone, or than an
adhesive made from a polypropylene/calcium carbonate compound comprising
less than 50% calcium carbonate by weight. Because of the higher thermal
conductivity using an adhesive 425 made from a compound of polypropylene
and calcium carbonate comprising at least 50% calcium carbonate by
weight, it is anticipated that it will set faster, and thus, apparatus
410 will operate at higher overall throughput than it would when using an
adhesive 425 comprising more than 50% polypropylene.

[0205] In an embodiment, the backing of cover 817 comprises polypropylene,
and the backing comprising polypropylene is in a layer having a thickness
of between 10 mil and 40 mil. In an embodiment, the backing layer of the
composite cover material 817 is approximately 10 mil, 15 mil, 20 mil or
25 mil thick. In an embodiment, the backing of the composite cover
material 817 is another suitable thickness.

[0206] In an embodiment, the backing of the composite cover material 817
is formed from a polypropylene/calcium carbonate compound comprising at
least 50%, but not more than 66% calcium carbonate by weight. In an
embodiment, the backing of the composite cover material 817 is formed
from a polypropylene/calcium carbonate compound comprising approximately
60% calcium carbonate by weight. The backing of the composite cover
material 817 formed from a polypropylene/calcium carbonate compound
comprising at least 50% calcium carbonate by weight, is expected to have
higher thermal conductivity than a backing made from polypropylene alone,
or than a backing made from a polypropylene/calcium carbonate compound
comprising less than 50% calcium carbonate by weight. Because of the
higher thermal conductivity using a composite cover material 817 having a
backing formed from a compound of polypropylene and calcium carbonate
comprising at least 50% calcium carbonate by weight, it is anticipated
that the adhesive 425 will set faster, and thus, apparatus 410 will
operate at higher overall throughput than it would when using a composite
cover material 817 having a backing formed from a compound of
polypropylene and calcium carbonate comprising more than 50%
polypropylene.

[0207] The following table presents illustrative paint rollers that will
be used in the discussion below.

[0208] The following table presents illustrative paint rollers that can be
formed using the invention disclosed herein. The "Cover" column refers to
the cover material 817 used, the "Adhesive" column refers to the adhesive
425 used, the "Strip 1" column refers to the strip 23 used and the "Strip
2" column refers to the strip 423 used in the example. As above, for each
column, the entry reflects the thickness in mil, and the percentage of
calcium carbonate (by weight) compounded with polypropylene to form the
component. The thickness in mil for the "Cover" column reflects the
thickness of the layer 425 used to form the composite cover material
817--the "Cover" column entries showing a thickness of 0 reflect the use
of a cover material rather than a composite cover material.

[0209] Example C1 and D1, each make paint rollers of the same thickness,
however, the characteristics of the paint roller D1 are substantially
improved when compared to those of C1. The D1 paint roller feels firmer
and is of higher quality than the C1 paint roller. Moreover, the 40 mil
thick core of the D1 paint roller uses only 42% of the polypropylene used
to manufacture the C1 paint roller (excluding any polypropylene in the
cover material).

[0210] Example D2 forms a paint roller with very good properties and
firmness. This roller compares favorably to Example D1 due to its extra
10 mil thickness. Moreover, Example D2 compare favorably not only to
Example C1, but to Example C2 having a core of the same thickness (50
mil), and even to Example C3, despite Example C3 having a core of 70 mil
and using substantially more than twice as much polypropylene. Example D3
makes an even better paint roller, while Example D4 makes an excellent
quality paint roller. Notably, while Example D4 is the same core
thickness as example C3, it uses only about 46% as much polypropylene.

[0211] As above, many other variations are possible. For example, it is
not necessary to use both a compound adhesive and a strip formed from
compounding polypropylene and calcium carbonate. Moreover, it is not
necessary to form both strips from a compound adhesive. In addition, it
is not necessary to use a composite cover material formed from a compound
of polypropylene/calcium carbonate. The use of (i) a compound strip, (ii)
compound adhesive or (ii) composite cover material formed from a compound
of polypropylene/calcium carbonate, will each produce a stronger roller,
with less polypropylene, than the use of same component made from
non-compound polypropylene.

[0212] Further, it has been observed that the two-strip 60 mil core roller
of Example C4 provides approximately the same qualities as the single
strip, 40 mil core roller of Example A2, while the latter roller uses
only about 37% as much polypropylene. Also, notably, the two-strip 50 mil
core Example D2 provides a much stronger roller than the two-strip 60 mil
core roller made according to Example C4.

[0213] Returning to FIG. 15, in an embodiment, one or both of the strips
445, 448 can be made from a compound of polypropylene and calcium
carbonate having at least 50%, but not more than about 66% calcium
carbonate by weight. Similarly, in an embodiment the cover 415 may having
a backing made of a compound of polypropylene and calcium carbonate
having at least 50% but not more than 66% calcium carbonate by weight. As
discussed above, the percentage of calcium carbonate used in the compound
forming the strips 448, 445 and the cover 415 backing may be the same, or
may differ from one-another.

[0214] In an embodiment, the strips 445, 448 are made from a compound of
polypropylene and calcium carbonate having approximately 60% calcium
carbonate, and the cover 415 has a backing made of a compound of 105 MFI
polypropylene and non-refined calcium carbonate having approximately 25%
calcium carbonate by weight.

[0215] Returning to FIG. 16, apparatus 500 may be operated according to
the present invention using a preformed core 540 made of a compound of
polypropylene and calcium carbonate having at least 50%, but not more
than 66% calcium carbonate by weight; and/or using a cover 520 having a
backing made of a compound of polypropylene and calcium carbonate having
between 5% and 66% calcium carbonate by weight. When more than one
component is made of a compound of polypropylene and calcium carbonate,
the percentage of calcium carbonate used in the compound forming the core
540 and the cover 520 backing may be the same, or may differ from
one-another. In an embodiment, the core 540 is made of a compound of
polypropylene and calcium carbonate comprising approximately 60% calcium
carbonate by weight, and the cover backing is made of a compound of
polypropylene and calcium carbonate comprising approximately 25% calcium
carbonate by weight.

[0216] As discussed above variation in the amount of calcium carbonate are
within the scope of the invention, and thus, it will be apparent to one
of skill in the art that to some degree thermal conductivity can be
controlled, or a desired thermal conductivity or range of thermal
conductivity can be achieved by varying the percentage of calcium
carbonate in one or more of the compounds. It will be apparent to one of
skill in the art that to some degree, stiffness can be controlled, or a
desired stiffness or range of stiffness can be achieved by varying the
percentage of calcium carbonate in these compounds as well.

[0217] It is possible, without departing from the invention, to use a
compound of polypropylene and calcium carbonate having between 50% and
60% calcium carbonate by weight in lieu of polypropylene in making paint
rollers. In light of this disclosure, other methods for the manufacture
of the same will be apparent to persons of skill in the art.

[0218] Benefits of certain embodiments of the instant invention include:
control of thermal conductivity in the component materials leading to
faster throughput and/or faster set times; and control of material
characteristics such as stiffness for manufacture of harder, more
expensive paint rollers.

Observations Made Since Filing U.S. Patent Application Ser. No. 12/463,876

[0219] Turning to FIG. 17, a functional drawing of the apparatus 1701 for
forming the composite paint roller cover 1751 having a backing is shown.
The composite cover material 1751 is formed using a supply of pile
material 1702 such as would be suitable for use manufacturing a paint
roller cover. The composite cover material is formed using a continuous
supply of such pile material. Suitable pile material 1702 includes
material like that manufactured using a sliver knitting machine such as
the SK-18 available from Mayer Industries Inc. Such knitted pile material
may be made "in the round," and slit for use as a continuous pile
material. Once slit, the knitted pile material can be laid flat for
further processing. As an alternative to the knitted pile material, a
woven pile material may be used. Such a woven pile material, while
generally more expensive than the knitted material, is advantageous as
its fibers are better locked in during the weaving process rather than by
later application of an adhesive. The knitted or woven pile material 1702
is usually sheared (not shown) on the pile side to attain a desired pile
height. As an alternative to woven or knitted materials, a microfiber
material may be used. The material 1702 can have any usable width, such
as widths of approximately 32'' or, for example between about 56'' and
62'', and can be manufactured or sheared to a desired pile height. In an
embodiment, the material has a pile side (shown facing downwards and
towards the left) and a fabric side (shown facing upwards and toward the
right).

[0220] In an embodiment, the material 1702 is laid flat with its pile side
down and may be moved across a tenter, a/k/a, a tenter frame. Other
apparatus may be used to advance the material 1702. In an embodiment, the
material 1702 is moved in a generally horizontal direction along surface
1790 with the pile side down towards roller 1780. The material 1702 is
then advanced, along with an adhesive layer 1720, toward a nip between
roller 1780 and counter-rotating roller 1785, where the adhesive layer
1720 and the material 1702 are urged together. Thereafter the thus joined
components 1751 are transferred to counter-rotating roller 1785, and
begin to cool. The joined components, or composite sheet material 1751 is
thereafter taken off the counter-rotating roller 1785 and advanced in a
generally horizontal direction. The composite sheet material may then be
transferred to a slitter (not shown) or slit in-line (not shown), into
strips of composite cover material suitable for use in manufacturing
paint rollers. In an embodiment, the material 1702 is advanced at a line
speed of at least 5 yards per minute, and more preferably more than 10
yards per minute. In an embodiment, the apparatus 1701 is operated at a
speed to between 12 and 20 yards per minute.

[0221] In an embodiment, a heat source 1703 is directed towards the fabric
side of the material 1702 as it advances. When a heat source 1703 is used
the heat source should be able to apply heat to the fabric side of the
material and raise the temperature thereof. Any kind of heat source 1703
may be used. In an embodiment, the heat source 1703 may be an infrared
heat source. In an embodiment, the heat source 1703 may be a resistive
heat element. In an embodiment, the heat source 1703 causes that surface
temperature on the fabric side of the material 1702 to reach at least
about 50 degrees C., or more preferably about 55 degrees C., prior to
reaching or making contact with roller 1780. In an embodiment, the heat
source 1703 causes that surface temperature on the fabric side of the
material 1702 to reach at least about 50 degrees C., but not more than 65
degrees C., prior to reaching or making contact with roller 1780. In an
embodiment, the heat source 1703 causes that surface temperature on the
fabric side of the material 1702 to reach at least 50 degrees C., but not
more than 95 degrees C., prior to reaching or making contact with roller
1780. In an embodiment, the heat source 1703 causes that surface
temperature on the fabric side of the material 1702 to reach
approximately the same temperature as the roller 1780, prior to making
contact with roller 1780.

[0222] The roller 1780 may be of any suitable diameter, and have a width
sufficient to support the advancing material 1702. In an embodiment, the
roller 1780 has a diameter of more than about 6'', preferably more than
about 12'', and more preferably about 24'' or around 65 cm. In an
embodiment, during use roller 1780 is maintained at a temperature that
deviates from the ambient temperature. In an embodiment, roller 1780 is
maintained at a temperature that is elevated above ambient temperature by
at least 15 degrees C., and preferably more than about 25 degrees C., and
more preferably between about 40 and 70 degrees C. above the ambient
temperature. In a typical paint roller manufacturing environment, ambient
temperature is typically between about 20 degrees C. and 30 degrees C.,
and frequently around 25 degrees C. In an embodiment, roller 1780 is
maintained at a temperature of more than 60 degrees C., but not more than
100 degrees C., and preferably between about 65 degrees C. and 95 degrees
C.

[0223] The material 1702 is advanced along roller 1780, pile side down
(i.e., in), for a portion of a rotation. In an embodiment where the
roller 1780 is maintained at a temperature that deviates from ambient
temperature, the temperature of the material 1702 may change in the
direction of the deviation as the material 1702 advances along the roller
1780. In an embodiment, the material 1702 is advance along roller 1780
for between about 1/5 and 1/4 of a revolution. In an embodiment, the
roller 1780 is heated above ambient temperature, and the material 1702 is
advance along roller 1780 for between about 1/5 and 1/4 of a revolution
thus increasing the temperature of at least a portion of the material
1702 contacting the roller 1780. In an embodiment, the roller 1780 is
heated to at least about 50 degrees C. to heat the material 1702 above
ambient temperature as it advances along roller 1780. In an embodiment,
the roller 1780 is heated to at least about 60 degrees C. but not more
than 100 degrees C. to heat the material 1702 above ambient temperature
as it advances along roller 1780. In an embodiment, the roller 1780 is
heated to between 65 degrees C. and 95 degrees C.

[0224] An applicator 1709 dispenses an adhesive layer 1720 between the
fabric side of material 1702 that has advanced along roller 1780 and a
second roller 1785. In an embodiment, the applicator 1709 is an extrusion
die head, and the adhesive layer 1720 is dispensed in a smoothly flowing
layer as extrudate from an extrusion process. In an embodiment, the
adhesive layer 1720 is dispensed in a generally vertical direction and
gravity carries the extrudate downward from the applicator 1709. As the
material 1702 advances in the apparatus 1701, the adhesive layer 1720 is
sandwiched between the fabric side of the material 1702 and a second
roller 1785. In an embodiment, the adhesive layer 1720 is extruded from
the applicator 1709, and is sandwiched between the fabric side of the
material 1702 and a second roller 1785 while the it is still in a molten,
or at least partially liquefied state. In an embodiment, after its
application to the fabric backing of the material 1702, the un-set
adhesive layer 1720 fills interstitial spaces or gaps within the fabric
backing of the material 1702 before setting, thus integrating the
adhesive layer 1720 with the material 1702, and forming a composite sheet
material 1751. In an embodiment, the adhesive layer 1720 is permitted to
cool and set once integrated with the fabric backing of the material
1702. The thusly formed composite sheet material 1715 is thicker, and may
be stiffer than the material 1702 absent the integrated materials from
the adhesive layer 1720. In an embodiment, the fibers of the of the
composite sheet material 1751 are better held in place, and thus less
likely to shed, by the integration of the adhesive layer 1720 with the
material 1702. In an embodiment, substantially all of the fibers of the
of the composite sheet material 1751 are locked in place by the
integration of the adhesive layer 1720 with the material 1702, and thus,
the composite sheet material can be use, once cut into strips as
discussed above, to make substantially shed-free paint roller covers.

[0225] In an embodiment (not shown), the material 1702 may be advanced in
a generally linear manner, not curving substantially around the rollers.
In such embodiment, the material 1702 may pass, pile-side-down, above a
first roller, and fabric-side-up beneath a second roller. In such
embodiment, applicator 1709 may dispense the adhesive layer 1720 onto the
fabric-side of the material 1702, onto the face of the second roller, or,
to both the fabric-side of the material 1702 and the face of the second
roller substantially simultaneously.

[0226] In an embodiment, the material 1702 and the adhesive layer 1720 are
advanced along roller 1785, pile side out and sandwiched adhesive layer
in, for a fraction of a revolution. In an embodiment, roller 1785 rotates
in a direction counter to the direction of rotation of roller 1780. In an
embodiment, the material 1702 and the adhesive layer 1720 are advanced
along the roller 1785 for approximately 1/5 to 1/4 of a revolution. In an
embodiment, the material 1702 and the adhesive layer 1720 are advanced
along the roller 1785 until they are returned to a generally horizontal
direction along apparatus 1701. In an embodiment, as the assembly
separates from the roller 1785, the adhesive layer 1720 has substantially
hardened and set, and is integrated into the material 1702, thus forming
a composite sheet material 1751. The composite sheet material 1751 may be
advanced, slit to form composite cover strips and the strips used in the
fabrication of paint rollers (not shown in FIG. 17).

[0227] The roller 1785 may be of any suitable diameter, and have a width
sufficient to support the advancing material 1702. In an embodiment, the
roller 1785 has a diameter substantially the same as the diameter of
roller 1780. In an embodiment, the roller 1785 has a width substantially
the same as the width of roller 1780. In an embodiment, during use roller
1785 is maintained at a temperature that deviates from the ambient
temperature. In an embodiment, roller 1785 is maintained at a temperature
that is below the ambient temperature by at least 5 degrees C., and is
preferably maintained at a temperature of between 5 and 15 degrees C. In
an embodiment, roller 1785 maintained at a temperature of more than about
10 degrees C. In an embodiment, roller 1785 maintained at a temperature
of less than about 13 degrees C.

[0228] In an embodiment, roller 1785 is maintained at a temperature of
between approximately 50 degrees C. and 100 degrees C. colder than roller
1780.

[0229] In an embodiment where the roller 1785 is maintained at a
temperature that deviates from ambient temperature, the temperature of
the adhesive layer 1720 and the fabric backing of material 1702 may
change in the direction of the deviation as the components advance along
the roller 1785. In an embodiment, the material 1702 is advance along
roller 1785 for between about 1/5 and 1/4 of a revolution. In an
embodiment, the roller 1780 is cooled below ambient temperature, and the
components forming the composite sheet material 1751 are advance along
roller 1785 for between about 1/5 and 1/4 of a revolution, decreasing the
temperature of the adhesive layer 1720 and the material 1702, and causing
the adhesive layer 1720 to more rapidly harden and set. In an embodiment,
the roller 1785 is chilled to at least about 15 degrees C. In an
embodiment, the roller 1785 is chilled to a temperature between 10
degrees C. and 15 degrees C.

[0230] Although shown relatively far apart in FIG. 17 for illustrative
purposes, the rollers 1780, 1785 may be close together. A nominal gap of
about five 1000ths of an inch (0.005'') is provided between the rollers
1780, 1785 to ensure that the rollers will not contact each other, as
such contact may cause damage to the rollers and/or entire apparatus
1701. In an embodiment, the distance between the rollers 1780, 1785 is
adjustable to permit variations in type of material 1702, the pile size
of the material 1702 and the desired thickness of the adhesive layer
1720, which is discussed further, below. In an embodiment, an adjustment
allows for management of the pressure applied between the rollers 1780,
1785 as the adhesive layer 1720 and the material 1702 pass there-between.
In an embodiment, the adhesive layer 1720 is sandwiched between the
fabric side of the material 1702 as it passes through the restricted
space between the rollers 1780, 1785, thus urging the adhesive layer 1720
into the interstitial pores in the fabric side of the material 1702. It
is believed by the inventor that the gathering of the components (the
adhesive layer 1720 and the material 1720) between the rollers 1780, 1785
in the manner shown and described may cause the portion of the adhesive
layer 1720 that first comes in contact with the roller 1785 to begin to
set while the portion of the adhesive layer 1720 that first comes in
contact with the material 1702 is still substantially in a molten or
partially liquefied state and able to integrating into the fabric backing
of the material 1702.

[0231] In an embodiment, the nip force, that is, a compressive force
imparted on the components (i.e., the material 1702 and adhesive layer
1720) as they pass between the rollers 1780, 1785 is at least 80 lbs. per
linear inch (PLI), and more preferably between 100 and 200 PLI, and most
preferably between about 150 and 175 PLI. In an embodiment, the nip force
is adjustable, and controlled by a pneumatic system (not shown) wherein
air pressure delivered to a piston will increase the nip force. In an
embodiment, the nip force can be adjusted to accommodate differing pile
thickness of the material 1702 and differing thickness of the adhesive
layer 1720. In an embodiment, about 80 PSI air pressure into a pneumatic
system will create approximately 150 PLI in nip pressure.

[0232] In an embodiment, the adhesive layer 1720 is has a thickness of
between about 0.005'' (5 mils) and 0.025'' (25 mils). In an embodiment,
the adhesive layer 1720 is as thin as practical to provide a composite
sheet material 1751 having a generally uniform backing. In an embodiment
the adhesive layer 1720 provides a composite sheet material 1751 having a
generally non-porous backing. In an embodiment, the resulting composite
sheet material 1751 has a non-pile backing of less than about 20 mils. In
an embodiment, composite sheet material 1751 has a non-pile backing of
less than about 15 mils. In an embodiment, composite sheet material 1751
has a non-pile backing of less than about 10 mils, or less than about 5
mils.

[0233] In an embodiment, the adhesive layer 1720 extruded from the
applicator 1709 is made at least partially from an thermoplastic
elastomer, and preferably from a polypropylene-based elastomer such as
the propylene-based elastomer available from ExxonMobile under the brand
name Vistamaxx. Polypropylene-based elastomers also include Sarlink 3170
from DSM Thermoplastic Elastomers Inc. (of Leominster, Mass.), and
several Dow Chemical Company specialty elastomers for thermoplastic
polyolefins.

[0234] In an embodiment, the propylene-based elastomer has density of
between 0.5 and 1 g/cm3, and preferably between about 0.75 and 0.9
g/cm3. In an embodiment, the propylene-based elastomer has a melt
index of greater than 1, and preferably at least 3. In an embodiment, the
propylene-based elastomer has a melt index of 5 or more. It is believed
that as the relative percentage by weight of propylene-based elastomer
increases in the backing compound, the melt flow would preferably be
higher. In an embodiment, the propylene-based elastomer comprises an
ethylene content of at least 5 wt. %, and preferably at least 10 wt. %.
In an embodiment, the propylene-based elastomer comprises an ethylene
content of at least 15 wt. %.

[0235] In an embodiment, the adhesive layer 1720 is made at least
partially from the polypropylene-based elastomer Vistamaxx 6202. In an
embodiment, the adhesive layer 1720 is made predominantly from the
polypropylene-based elastomer Vistamaxx 6202. Vistamaxx 6202 is reported
by ExxonMobile to have a density (ASTM D1505) of 0.861 g/cm3, a melt
index (ASTM 1238) of 7.4 g/10 min. and a melt mass-flow rate melt index
(ASTM 1238) of 18 g/10 min. Vistamaxx 6202 is reported by ExxonMobile to
have an ethylene content (ASTM D3900) of 15.0 wt. %.

[0236] In an embodiment, the adhesive layer 1720 comprises a
polypropylene-based elastomer and calcium carbonate. In an embodiment,
the adhesive layer 1720 is a compound comprising a polypropylene-based
elastomer such as Vistamaxx 6202 and at least about 15 wt. %, but not
more than 66 wt. %, calcium carbonate. In an embodiment, the adhesive
layer 1720 is a compound comprising a polypropylene-based elastomer such
as Vistamaxx 6202 and between about 20 and 50 wt. % calcium carbonate. In
an embodiment, the adhesive layer 1720 is a compound comprising a
polypropylene-based elastomer such as Vistamaxx 6202 and between about 25
and 33 wt. % calcium carbonate.

[0237] In an embodiment, the adhesive layer 1720 further comprises
polypropylene, thus making it a compound comprising a polypropylene-based
elastomer, calcium carbonate and polypropylene. Thus, in an embodiment,
the adhesive layer 1720 is a compound comprising a polypropylene-based
elastomer such as Vistamaxx 6202 and between about 15 and 50 wt. %
calcium carbonate and between about 5 and 30 wt. % polypropylene.

[0238] More generally, the above-describe inventive adhesive material
comprising an polypropylene-based elastomer may be used in connection
with the apparatus described in FIGS. 1-11, 13 and 16.

Example 1

[0239] An adhesive layer was formed by compounding 85 wt. % Vistamaxx 6202
and 15 wt. % calcium carbonate. Composite sheet material was made by
passing a material over a first heated roller, and as the material
received an adhesive layer, under a second cooled roller, substantially
in the layout shown in FIG. 17. The composite sheet material was tested
for its ability to lock fibers and in other subjective and objective
ways, and the results were deemed acceptable for use as a composite cover
material once slit into strips.

Example 2

[0240] An adhesive layer was formed by compounding 80 wt. % Vistamaxx
6202, wt. % calcium carbonate and 5 wt. % 4920WZ-US polypropylene resin.
Composite sheet material was made otherwise as in Example 1 above. The
composite sheet material was tested for its ability to lock fibers and in
other subjective and objective ways, and the results were deemed
acceptable, and better than the results for Example 1, for use as a
composite cover material once slit into strips.

Example 3

[0241] An adhesive layer was formed by compounding 55 wt. % Vistamaxx
6202, wt. % calcium carbonate and 15 wt. % 4920WZ-US polypropylene resin.
Composite sheet material was made otherwise as in Example 1 above. The
composite sheet material was tested for its ability to lock fibers and in
other subjective and objective ways, and the results were deemed very
good, and substantially better than the results for Example 1 or 2, for
use as a composite cover material once slit into strips.

[0243] Melt Flow: It has been discovered that the compounding of calcium
carbonate with polypropylene--while not predictably affecting the
resulting compound's melt flow--will affects the material's
extrudability, that is, the ability of the material to be extruded in a
smoothly flowing layer such as the adhesive layer 1720 that may be used
to form the composite sheet material 1751, and composite strip material,
discussed above. Accordingly, where substantial amounts of calcium
carbonate are part of the extrudate, to achieve a smoothly flowing layer
of adhesive, it has been found that the polypropylene should have an
elevated melt flow from what would otherwise be used.

[0244] Surface Treatment: In further experiments, the manufacture of
strips using refined calcium carbonate in combination with polypropylene,
e.g., calcium carbonate that has been surface treated, has been found to
add strength to the resulting paint roller product when compared to a
strip made from a combination of non-refined calcium carbonate in
combination with polypropylene. Thus, in an embodiment, the calcium
carbonate compounded with polypropylene to form the strips, may be a
non-refined or refined calcium carbonate, but is preferably a refined
calcium carbonate. The calcium carbonate compounded with polypropylene to
form the adhesives or composite cover material, may be a non-refined or
refined calcium carbonate, and while some advantages seem apparent in
using refined calcium carbonate, either combination makes acceptable
products. In an embodiment, the refined calcium carbonate is used in a
relatively fine, powdered form. In an embodiment the calcium carbonate
may have a median particle size of 3 micrometers or less.

[0245] Turning now to FIG. 18, a cutaway side view diagrammatic
representation of a portion of an applicator 1801 for use in an
embodiment of the present invention is shown. As shown in FIG. 18, the
applicator body 1805 designed for use with two separate extruders forms a
cavity within. In an embodiment, the cavity has two openings 1814, 1819
at one end, and a single opening 1811 at the other. A first adhesive 1815
may be extruded into the first opening 1814, while at the same time, a
second adhesive 1820 may be extruded through the second opening 1819. The
two materials 1815, 1820 may be mechanically separated by a separator
1810 at the point they enter the cavity, and for some distance into the
cavity. In an embodiment, once the adhesive materials 1815, 1820 are past
the separator 1811, but while still within the applicator 1801 cavity,
they may contact each other, and run through the cavity in contact with
each other.

[0246] In an embodiment, the applicator 1801, which may be an extrusion
die head, is used in lieu of applicator 1709 (see FIG. 17) in apparatus
1701 for forming the composite paint roller cover 1751. When so used,
applicator 1801 can coextrude a polypropylene based adhesive material
alongside a propylene-based elastomer adhesive material for use as the
adhesive 1720 layer. More specifically, applicator 1801 may dispense an
adhesive layer 1720 formed from first and second adhesive materials 1815,
1820. As shown in FIG. 17, the adhesive layer 1720 may be dispensed
between the fabric side of material 1702 and a roller 1785. The adhesive
layer 1720 formed from first and second adhesive materials 1815, 1820 is
dispensed in a smoothly flowing layer as extrudate from a coextrusion
process. The adhesive layer 1720 may be dispensed in a generally vertical
direction and thus gravity may carry the extrudate downward from the
applicator 1801. After being dispensed in a smoothly flowing layer, the
adhesive layer 1720 formed from first and second adhesives 1815, 1820 may
be sandwiched between the fabric side of the material 1702 and the second
roller 1785 while the it is still in a molten, or at least partially
liquefied state.

[0247] In an embodiment, the first adhesive material 1815 is coextruded on
the material 1702 side (as opposed to the roller 1785 side) while the
second adhesive material 1820 coextruded on the roller 1785 side (as
opposed to the material 1702 side). In an embodiment, the first adhesive
material 1815 comprises a propylene-based elastomer, while the second
adhesive material 1820 comprises propylene (as opposed to an elastomeric
polypropylene).

[0248] After application of the adhesive layer 1720 formed from the first
and second adhesive materials 1815, 1820 to the fabric backing of
material 1702, the un-set adhesive 1815 may fill the interstitial spaces
or gaps within the fabric backing of the material 1702 before setting,
thus integrating with the material 1702, while the un-set adhesives 1815,
1820 may to some extent integrate with each other. Thus, forming a
composite sheet material 1751 upon setting. In an embodiment, the
adhesive layer 1720 formed from first and second adhesives 1815, 1820 is
permitted to cool and set once integrated with the fabric backing of the
material 1702. The thusly formed composite sheet material 1715 is
thicker, and may be stiffer than the material 1702 absent the integrated
materials from the adhesive layer 1720. In an embodiment, the fibers of
the of the composite sheet material 1751 are better held in place, and
thus less likely to shed, by the integration of the adhesive layer 1720
with the material 1702. In an embodiment, substantially all of the fibers
of the of the composite sheet material 1751 are locked in place by the
integration of the adhesive layer 1720 with the material 1702, and thus,
the composite sheet material can be use, once cut into strips as
discussed above, to make substantially shed-free paint roller covers.

[0249] In an embodiment, the adhesive material 1815 comprises a
polypropylene-based elastomer and calcium carbonate. In an embodiment,
the adhesive material 1815 is a compound comprising a polypropylene-based
elastomer such as Vistamaxx 6202 and at least about 15 wt. %, but not
more than 66 wt. %, calcium carbonate. In an embodiment, the adhesive
material 1815 is a compound comprising a polypropylene-based elastomer
such as Vistamaxx 6202 and between about 20 and 50 wt. % calcium
carbonate. In an embodiment, the adhesive material 1815 is a compound
comprising a polypropylene-based elastomer such as Vistamaxx 6202 and
between about 30 and 45 wt. % calcium carbonate.

[0250] In an embodiment, the adhesive material 1820 comprises compound of
polypropylene and calcium carbonate. In an embodiment, the second
adhesive material 1820 is a compound comprising polypropylene and at
least about 33 wt. %, but not more than 66 wt. %, calcium carbonate. In
an embodiment, the adhesive material 1820 is a compound comprising
polypropylene and between about 50 and 66 wt. % calcium carbonate. In an
embodiment, the second adhesive 1820 is a compound comprising
polypropylene and between about 50 and 60 wt. % calcium carbonate.

Example 4

[0251] An adhesive layer was made by coextruding a first adhesive formed
by compounding 60 wt. % Vistamaxx 6202 and 40 wt. % calcium carbonate and
a second adhesive formed by compounding 40 wt. % Total Petrochemical
4920WZ-US and 60 wt. % calcium carbonate. Composite sheet material was
made by passing a material over a first heated roller pile side down, and
then sandwiching the adhesive layer between the material and a second
cooled roller, substantially in the layout shown in FIG. 17, but, as
described above, applying a nip force in excess of about 150 PLI.

Example 5

[0252] An adhesive layer was made by coextruding a first adhesive formed
by compounding 80 wt. % Vistamaxx 6202 and 20 wt. % calcium carbonate and
a second adhesive formed by compounding 40 wt. % Total Petrochemical
4920WZ-US and 60 wt. % calcium carbonate. Composite sheet material was
made by passing a material over a first heated roller pile side down, and
then sandwiching the adhesive layer between the material and a second
cooled roller, substantially in the layout shown in FIG. 17, but, as
described above, applying a nip force in excess of about 150 PLI.

[0253] FIG. 19 is a diagrammatic side view representation of an apparatus
1901 for sheet-forming according to an embodiment of the present
invention. An applicator 1909, which may be an extrusion die head,
extrudes a smoothly flowing layer of an extrudate 1920 comprising
polypropylene and calcium carbonate. The extrudate 1920 is fed into the
nip between first roller 1950 and second roller 1955. In an embodiment,
the nip between the first roller 1950 and second roller 1955 is of
sufficiently large size to permit the smoothly flowing layer of extrudate
1920 to pass there-through, but of sufficiently small size to impart
pressure upon the extrudate 1920 so as to flatten and/or emboss it. In an
embodiment, the nip between the first roller 1950 and second roller 1955
is adjustable either in spacing or in pressure, or both. After the
extrudate 1920 passes through the nip between the first roller 1950 and
second roller 1955, it becomes more sheet-like, forming molten sheet
1921. In an embodiment, molten sheet 1921 is transferred along second
roller 1955 and fed into the nip between second roller 1955 and third
roller 1960. As with the preceding nip, the nip between second roller
1955 and third roller 1960 is of sufficiently large size to permit the
molten layer 1921 to pass there-through, but of sufficiently small size
to impart pressure upon the molten layer 1920 so as to further flatten
and/or emboss it. Also as with the preceding nip, in an embodiment, the
nip between the second roller 1955 and third roller 1960 is adjustable
either in spacing or in pressure, or both. After the molten sheet passes
through the nip between the second roller 1955 and third roller 1960, and
is transferred along the third roller 1960 for a fraction of a rotation,
it may become sufficiently set to permit it to be transferred off the
roller support, and travel to slitting station (not shown) to slit the
sheet into strips.

[0254] In an embodiment, the smoothly flowing layer of extrudate 1920
comprises compound of polypropylene and calcium carbonate. In an
embodiment, the smoothly flowing layer of extrudate 1920 is a compound
comprising polypropylene and at least about 33 wt. %, but not more than
66 wt. %, calcium carbonate. In an embodiment, the smoothly flowing layer
of extrudate 1920 is a compound comprising polypropylene and between
about 50 and 66 wt. % calcium carbonate. In an embodiment, the smoothly
flowing layer of extrudate 1920 is a compound comprising polypropylene
and between about 50 and 60 wt. % calcium carbonate. In one embodiment,
the smoothly flowing layer of extrudate 1920 is formed by compounding
between about 40 and 50 wt. % Total Petrochemical 4920WZ-US and between
about 60 and 50 wt. % calcium carbonate.

[0255] The above embodiments and preferences are illustrative of the
present invention. It is neither necessary, nor intended for this patent
to outline or define every possible combination or embodiment. The
inventor has disclosed sufficient information to permit one skilled in
the art to practice at least one embodiment of the invention, and has
disclosed the ways the inventor now believes are the best ways to
practice the invention. The above description and drawings are merely
illustrative of the present invention and that changes in components,
structure and procedure are possible without departing from the scope of
the present invention as defined in the following claims. Thus, while the
invention has been particularly shown and described with reference to
embodiments thereof, it will be understood by those skilled in the art
that various changes in form and details may be made therein without
departing from the spirit and scope of the invention. The above
embodiments are illustrative of the present invention. It is neither
necessary, nor intended for this patent to outline or define every
possible combination or embodiment.